Wall assembly and construction method with wall assemblies

Abstract

Wall assembly comprising a first layer (10) and a second layer (20), attached to opposed sides of an intermediate layer (30) made of an insulant material; an inner load bearing structure (40) embedded in the intermediate layer (30), wherein the first layer (10) comprises multiple first panels (11), arranged coplanar, laterally adjacent to and in contact with each other at their peripheral edges (12), and the second layer (20) comprises multiple second panels (21), arranged coplanar, laterally adjacent to and in contact with each other at their peripheral edges (22); the intermediate layer (30) comprises one third layer, or two overlapped and attached third layers, each being made of multiple insulant panels (31) arranged coplanar, laterally adjacent to and in contact with each other at their peripheral edges (32).

Description

Technical field

[0001] The present invention relates to a wall assembly, and to a construction method with said wall assemblies.

[0002] The wall assembly is formed by first and second panels adhered on both sides of an intermediate layer made of insulant panels, the intermediate layer including an inner load bearing structure embedded therein which provides structural integrity to the wall assembly.

[0003] The construction method describes a method to produce such wall assemblies and to aggregate multiple wall assemblies forming a building structure.

[0004] The proposed wall assembly can be produced in an efficient and cheap manner in a factory, and later can be transported to a building site to become part of the load bearing structure of the building together with other wall assemblies and structural floor slabs connected thereto.Background of the Invention

[0005] Prefabricated wall assemblies are known, for example through documents WO2015090190A1 or US2006016143A1.

[0006] Those documents describe a prefabricated wall assembly comprising a first layer made of a single first panel and a second layer made of a single second panel attached on opposed sides of an interposed insulant panel. Each wall assembly comprises a recess on the peripheral sides, so that when two wall assemblies are placed adjacent to each other said recesses create a cavity where rebars can be inserted and concrete can be poured.

[0007] According to this solution, the size of the wall assembly is limited to the size of the first panel and to the size of the second panel, limiting the size of the wall assembly and increasing the work to be made in the building site by attaching several wall assemblies of small size.

[0008] Another handicap of the solution described in those documents is that the concrete is to be poured in a cavity coincident with a joint defined between adjacent wall assemblies, said joint extending along the entire longitude of the cavity, so that the poured concrete is likely to be filtered through said joint.

[0009] Also, those documents do not include an inner load bearing structure embedded in the intermediate layer.

[0010] The present invention solves the above and other problems.Description of the Invention

[0011] According to a first aspect, the present invention concerns a wall assembly as defined in claim 1.

[0012] The proposed wall assembly is a prefabricated wall assembly which comprises: an intermediate layer made of insulant material; a first layer and a second layer, attached to opposed sides of the intermediate layer; an inner load bearing structure housed between the first layer and the second layer, embedded in the intermediate layer, the inner load bearing structure comprising at least one beam, extending along the entire longitude of the intermediate layer, and multiple parallel columns perpendicular to the beam and extending along the entire height of the intermediate layer.

[0013] It will be understood that the term "layer" determines a flattened geometry defining two main faces.

[0014] Similarly, any reference to a bottom edge, top edge or side edge, or to a width, height or thickness of the wall assembly or of any element thereof, is made with the wall assembly in its final vertical position, it being understood that these geometric references will not change even if the wall assembly or its components are not in that final vertical position.

[0015] Accordingly, the width, or longitude, will be measured in a horizontal direction parallel to the main surfaces of the layers, the height will be measured in a vertical direction parallel to the main surfaces of the layers and the thickness will be measured in a horizontal direction perpendicular to the main surfaces of the layers.

[0016] According to the above, the proposed wall assembly comprises an intermediate layer made of a insulant material, a first layer facing one of the main faces of the intermediate layer and attached thereto, and a second layer facing the opposite main face of the intermediate layer and attached thereto, thus being the intermediate layer sandwiched between the first and second layers.

[0017] The resulting wall assembly will have one first surface, on the exposed main surface of the first layer, one second surface, on the exposed main surface of the second layer, parallel and opposed to the first surface, and four peripheral sides connecting the first and second surfaces, corresponding to two lateral sides, one upper side and one lower side. As explained before, those positional references such upper and lower, are maintained even if the wall assembly is not in vertical position.

[0018] The intermediate layer includes, embedded therein and thus comprised between the first and second layers, an inner load bearing structure. The inner load bearing structure is a monolithic structure made, for example, of concrete with rebars embedded therein.

[0019] The proposed inner load bearing structure comprises several columns, extending vertically from the bottom to the top of the wall assembly, and at least one beam connecting all the columns, said beam extending along the entire width of the wall assembly.

[0020] Preferably, said at least one beam includes one beam, which is adjacent to the top edge of the wall assembly.

[0021] This inner load bearing structure provides structural strength to the wall assembly to support structural loads of the building where it is to be integrated.

[0022] The wall assembly can include doorways or window openings.

[0023] The present invention further proposes, in a manner not known in the available state of the art, the following features: the first layer comprises multiple first panels, each of a predefined shape and dimension, arranged coplanar, laterally adjacent to and in contact with each other at their peripheral edges, and the second layer comprises multiple second panels, each of a predefined shape and dimension, arranged coplanar, laterally adjacent to and in contact with each other at their peripheral edges; the intermediate layer comprises one third layer, or two overlapped and attached third layers, each third layer being made of multiple insulant panels arranged coplanar, laterally adjacent to and in contact with each other at their peripheral edges, the peripheral edges of the insulant panels being misaligned with the peripheral edges of the first panels and of the second panels; and each pair of adjacent first panels are attached to the same insulant panel and each pair of adjacent second panels are attached to the same insulant panel.

[0024] According to the above, the first layer is not a monolithic layer, but a layer formed by several first panels arranged adjacent and laterally in contact to each other, and similarly the second layer is a layer formed by several second panels arranged adjacent and laterally in contact to each other. Also, the intermediate layer is a layer formed by several insulating panels arranged adjacent and laterally in contact with each other.

[0025] This construction allows the obtention of a wall assembly of a big size using panels of smaller size, which can be prefabricated in a standardized and cheaply manner.

[0026] In this case, the joints defined between perimetral edges of adjacent insulant panels are misaligned with the joints defined between the perimetral edges of adjacent first panels constitutive of the first layer and are also misaligned with the joints defined between the perimetral edges of adjacent second panels constitutive of the second layer.

[0027] The term 'misaligned' shall be understood to mean that the perimeter edge of a insulant panel is not parallel and coincident with a perimeter edge of a first panel or of a second panel, always existing an offset between a perimeter edge of an insulant panel and the perimeter edge of the first and second panels adhered to it, but does not exclude that a perimeter edge of a insulant panel could be transverse, for example perpendicular, to a perimeter edge of the first and second panels adhered thereto.

[0028] Thanks to this offset existing between the perimeter edges of the panels constitutive of the different layers of the wall assembly, two adjacent first panels are always adhered to a single insulant panel, and two adjacent second panels are also always adhered to a single insulant panel. Thus, the insulant panels act as connectors between adjacent panels thanks to this misalignment, providing fixation between them forming a monolithic assembly.

[0029] This misalignment ensures that no open gap is left, which could expedite penetration of water, or cold air through the wall assembly, and also ensures that no direct communication exists between the inner load bearing structure and the exterior of the wall assembly through said edges, reducing thermal bridges and also enabling the use of the first layer and intermediate layer, and optionally also the second layer when the wall assembly is in vertical orientation, as lost formwork for the fabrication of the inner load bearing structure, the misalignment preventing leakages of the poured concrete.

[0030] The intermediate layer can be formed by a single third layer made of adjacent insulant panels, with the inner load bearing structure being embedded on said third layer.

[0031] Alternatively, the intermediate layer can be made of two overlapped third layers attached to each other, for example through adhesives. In this case, preferably the inner load bearing structure is embedded in the third layer attached to the first layer, and the other third layer is overlapped to the third layer containing the inner load bearing structure interposed between the inner load bearing structure and the second layer providing thermal insulation.

[0032] The first and second panel are rigid panels, typically made of a cementitious material, or made of cement bonded cellulose fibers or made of any material comprising cement as an agglomerant. Preferably, the first and second panels do not include internal metallic rebars but merely reinforcement metallic, plastic, mineral or vegetal fibers embedded therein. The use of non-metallic fibers is preferred to avoid corrosion, allowing the use of panels with a reduced thickness, for example with a thickness comprised between 6mm and 30mm, or comprised between 6mm and 20mm.

[0033] Similarly, the insulant panels are panels made of an insulant material, preferably a rigid insulant material such expanded polystyrene. The thickness of the intermediate layer can be comprised, for example, between 8cm and 45cm, depending on the loads to be supported by the wall assembly. For example, an intermediate layer with a thickness comprised between 8cm and 15cm can contain only a thin inner load bearing structure, which will be suited to supporting small loads such as a light roof-top. An intermediate layer with a thickness comprised between 15cm to 45cm can contain a thicker inner load bearing structure, which is well suited to supporting different structural loads, for example of a multi-storey building.

[0034] The first and second panels can be attached on opposed sides of the intermediate layer, for example, with adhesives and / or with screws and / or with nails and / or with spiked elements glued to the first and second panels and inserted into the insulating panels.

[0035] The adhesives can be applied on one or both facing surfaces of the first layer and intermediate layer and on one or both facing surfaces of the second layer and intermediate layer.

[0036] The screws can be bolted for example in a nut embedded in the intermediate layer through a hole of the first layer or of the second layer. The nut can be an elongated nut with the same thickness as the intermediate layer, being simultaneously screwed on both sides to the first layer and to the second layer.

[0037] The nails can be nailed through the first layer and through the second layer into the intermediate layer, for example using a nail pistol.

[0038] The spiked elements can be adhered on the surface of the first layer and of the second layer facing the intermediate layer, and the spiked elements will be inserted into the intermediate layer by pushing the insulant panels of the intermediate layer against the first layer or by pushing the second panels of the second layer against the intermediate layer, nailing the first layer, the intermediate layer and the second layer together.

[0039] According to a second aspect, the present invention is directed to a construction method with wall assemblies, as described in claim 10. The proposed method comprises building a wall assembly by: forming a first layer; forming an intermediate layer by attaching an insulant material to the first layer; forming a second layer attached to the intermediate layer; forming an inner load bearing structure housed between the first layer and the second layer, embedded in the intermediate layer, the inner load bearing structure comprising at least one beam extending along the entire longitude of the intermediate layer, and multiple parallel columns perpendicular to the beam extending along the entire height of the intermediate layer;

[0040] The building of the wall assembly further comprises: the forming of the first layer comprises arranging multiple first panels, each of a predefined shape and dimension, coplanar, laterally adjacent to and in contact with each other at their peripheral edges according to a predefined disposition, the forming of the intermediate layer comprises arranging one third layer by arranging multiple insulant panels, each of a predefined shape and dimension, coplanar, laterally adjacent to and in contact with each other at their peripheral edges according to a predefined disposition, misaligning the peripheral edges of the insulant panels with the peripheral edges of the first panels, while attaching the insulant panels over the first layer defining a first assembly; the forming of the inner load bearing structure comprises: cutting or carving, during a first operation, an inner housing on the third layer of the first assembly, the inner housing comprising at least one beam channel extending along the entire longitude of the intermediate layer, and a plurality of parallel column channels, each extending along the entire height of the intermediate layer; housing within the inner housing, during a second operation, a prefabricated load bearing structure or an inner rebar assembly precursor of the inner load bearing structure to be later embedded in concrete poured and hardened in the inner housing during a third operation; the forming of the second layer is performed after the second operation or after the third operation or between the second and third operations, and comprises arranging multiple second panels, each of a predefined shape and dimension, coplanar, laterally adjacent to and in contact with each other at their peripheral edges, misaligning the peripheral edges of the second panels with the peripheral edges of the insulant panels on which the second panels are attached; transporting the wall assembly to a building site after forming the second layer or after forming the second layer and before performing the third operation and connecting the wall assembly to other adjacent wall assemblies.

[0041] According to the above, the building method starts assembling the first layer by placing a plurality of first panels adjacent to each other, laterally in contact by their side edges, closing any gaps between them, forming closed joints.

[0042] Then, a third layer of the intermediate layer is formed on top of the first layer, creating the first assembly, by placing a plurality of insulant panels adjacent to each other, laterally in contact by their side edges, closing any gaps between them, forming closed joints, and ensuring that the closed joints between adjacent insulant panels are not aligned with the closed joints between adjacent first panels of the first layer, creating an offset between the closed joints between insulant panels and the closed joints between first panels.

[0043] Preferably, adhesive is applied on the surface of the first panels and / or on the surface of the insulant panels facing each other. Other attachments are also proposed, such screws, nails and / or spiked elements glued to the first panels, as described above.

[0044] Preferably, the first layer is assembled in a horizontal position, and the insulant panels are assembled over the first layer forming the intermediate layer also in horizontal position. An alternative embodiment according to which the first layer and the intermediate layer are assembled in a tilted position or in a vertical position is also envisaged.

[0045] Then, the third layer of the first assembly is cut or carved, creating an inner housing on the intermediate layer shaped for tightly housing the inner load bearing structure within the intermediate layer.

[0046] This inner housing is cut or carved during a first operation performed before the assembly of the second layer, when one of the two main surfaces of the third layer is still exposed, allowing the cut or carving to be executed on said exposed main surface of the intermediate layer.

[0047] The inner housing comprises multiple parallel column channels, each extending from bottom to top of the intermediate layer, and at least one beam channel, each extending from one lateral side to the opposed lateral side of the intermediate layer, intersecting all the column channels.

[0048] Preferably, the cut or carving does not reach the first layer, a slimmed-down portion of the third layer remaining between the column channels and the beam channels and the first layer, providing some thermal insulation of the inner load bearing structure.

[0049] The cutting or carving can be performed, for example, using a hot wire foam cutter, a power saw, a milling machine or a combination thereof. This operation can be performed manually by an operator, or automatically by an automatic cutting or carving machine according to a preprogramed pattern.

[0050] Once the inner housing has been formed in the third layer, a prefabricated load bearing structure can be tightly inserted in the inner housing during a second operation, for example a prefabricated concrete monolithic structure prefabricated with the exact same shape as the inner housing, said prefabricated load bearing structure becoming the inner load bearing structure.

[0051] Alternatively, after the first operation of cutting or carving the inner housing, an inner rebar assembly is inserted in the inner housing during the second operation instead of the prefabricated load bearing structure.

[0052] The inner rebar assembly is a tridimensional mesh of interconnected metallic rebars comprising multiple parallel columns meshes and at least one beam mesh interconnected, the inner rebar assembly having a shape and size complementary with the shape and size of the inner housing.

[0053] The inner rebar assembly is a precursor of the inner load bearing structure, which is obtained by embedding the inner rebar assembly in concrete poured and hardened within the inner housing during a third operation.

[0054] Said third operation of pouring and hardening the concrete can be performed before the assembly of the second layer, with the first assembly in horizontal position, or can be performed after the assembly of the second layer, with the wall assembly horizontal, vertical or in another orientation.

[0055] The second layer is formed on top of the intermediate layer, after inserting the prefabricated load bearing structure in the inner housing, after inserting the inner rebar assembly in the inner housing and before pouring the concrete therein, or after inserting the inner rebar assembly in the inner housing and after pouring the concrete therein, creating the first assembly.

[0056] The second layer is formed by placing a plurality of second panels adjacent to each other, laterally in contact by their side edges, closing any gaps between them, forming closed joints, and ensuring that the closed joints between adjacent second panels are not aligned with the closed joints between adjacent insulant panels of the intermediate layer, creating an offset between the closed joints between second panels and the closed joints between insulant panels.

[0057] Preferably, glue is applied on the surface of the second panels and / or on the surface of the insulant panels facing each other. Other attachments are also proposed, such screws, nails and / or spiked elements glued to the second panels, as described above.

[0058] Optionally, before the formation of the second layer, the method can further comprise arranging an additional third layer made of multiple insulant panels, each of a predefined shape and dimension, coplanar, laterally adjacent to and in contact with each other at their peripheral edges according to a predefined disposition, the additional third layer being overlapped and attached to the previously formed third layer of the first assembly, the second layer being formed and attached over said additional third layer of the intermediate layer.

[0059] This additional third layer provides thermal and / or acoustic insulation between the inner housing and the second layer.

[0060] It will be understood that references to geometric position, such as parallel, perpendicular, tangent, etc. allow deviations up to ± 5° from the theoretical position defined by this nomenclature.

[0061] It will also be understood that any range of values given may not be optimal in extreme values and may require adaptations of the invention to these extreme values are applicable, such adaptations being within reach of a skilled person.Brief description of the Figures

[0062] The foregoing and other advantages and features will be more fully understood from the following detailed description of an embodiment with reference to the accompanying drawings, to be taken in an illustrative and non-limitative manner, in which: Fig. 1 shows an exploded perspective view of the wall assembly according to a first embodiment comprising a first layer made of four first panels, an intermediate layer made of nine insulant panels a second layer made of four second panels, and an inner load bearing structure made of a prefabricated load bearing structure inserted into the inner housing of the intermediate layer. Fig. 2 shows the same exploded perspective as Fig. 1 but according to a second embodiment in which an inner rebar assembly, precursor of the inner load bearing structure, is inserted into the inner housing of the intermediate layer, and in which a sealing plate is installed in each peripheral opening of the inner housing 70 accessible through the two lateral and the bottom peripheral sides of the first assembly before performing the third operation. Fig. 3 shows an exploded perspective view of the wall assembly according to a third embodiment, similar to the embodiment shown in Fig. 2, but including an additional third layer made of insulant panels interposed between the first assembly and the second layer, the building utilities channels being cur and / or carved on said additional third layer. Fig. 4 shows a view of the first assembly, comprising the first layer and one third layer adhered thereto, the insulant panels where the areas of the third layer to be cut or carved are signaled by printing, scoring, or projecting before the formation of the second layer. Fig. 5 shows the same first assembly shown in Fig. 4 after performing the first operation of cutting or carving the insulant panels. Detailed Description of the Invention and of particular embodiments

[0063] According to a first aspect, the present invention is directed to a wall assembly as described in claim 1.

[0064] The proposed wall assembly comprises a first layer 10 and a second layer 20, attached to opposed sides of an intermediate layer 30 made of an insulant material.

[0065] The intermediate layer 30 includes, embedded therein, an inner load bearing structure 40 housed between the first layer 10 and the second layer 20.

[0066] The inner load bearing structure 40 comprises at least one beam 41, extending along the entire longitude of the intermediate layer 30, transversely to the wall assembly, and multiple parallel columns 42 perpendicular to the beam 41 and extending along the entire height of the intermediate layer 30.

[0067] The inner load bearing structure 40 is preferably made of reinforced concrete, containing an embedded inner rebar assembly.

[0068] The first layer 10 comprises multiple first panels 11, each of a predefined shape and dimension, arranged coplanar, laterally adjacent to and in contact with each other at their peripheral edges 12.

[0069] The second layer 20 comprises multiple second panels 21, each of a predefined shape and dimension, arranged coplanar, laterally adjacent to and in contact with each other at their peripheral edges 22.

[0070] Preferably, the first and second panels 11, 21 are cementitious panels made of cementitious material, or are cementitious panels made of cement bonded cellulose fibers.

[0071] The use of cellulose fibers reduces cost, weight and environmental impact of the panel, and also increases the thermal insulating properties of the panel. The use of cement as bonding material provides an excellent compression strength and also provides the panel with flame-retardant properties.

[0072] Despite the above, first and second panels 11, 21, made of other materials are also envisaged.

[0073] According to a preferred embodiment, the first and second panels 11, 21 are thin and light panels having a thickness comprised between 6mm and 30mm, and preferably between 6mm and 20mm.

[0074] Similarly, the intermediate layer 30 comprises one third layer, or two overlapped and attached third layers, each third layer being made of multiple insulant panels 31 arranged coplanar, laterally adjacent to and in contact with each other at their peripheral edges 32, the peripheral edges 32 of the insulant panels 31 being misaligned with the peripheral edges 12, 22 of the first panels 11 and of the second panels 21.

[0075] Preferably, the intermediate layer has a thickness comprised between 8cm and 45cm, providing an excellent thermal insulation and completely housing the inner load bearing structure 40 in its interior. Insulant panels 31 are made of an insulant material, preferably a rigid insulant material such as expanded polystyrene, extruded polystyrene, polyurethane, or rigid mineral wool.

[0076] When the intermediate layer comprises one single third layer, the inner load bearing structure 40 is completely embedded in said third layer, but when the intermediate layer comprises two overlapped third layers, then it is proposed to embed the inner load bearing structure 40 on the third layer attached to the first layer 10, and to interpose the other third layer between the inner load bearing structure 40 and the second layer 20 providing thermal and / or acoustic insulation to the inner load bearing structure 40. In this case, the third layer attached to the second layer is much thinner, for example with a thickness comprised between 4cm and 15cm, than the third layer containing the inner load bearing structure, for example with a thickness between 21cm and 41cm. This embodiment is shown, for example, in Fig. 3.

[0077] Each pair of adjacent first panels 11 are attached to the same insulant panel 31 and each pair of adjacent second panels 21 are attached to the same insulant panel 31. In this way, the insulating panels 31 act as connectors between the adjacent first panels 11 and between adjacent second panels 21.

[0078] According to one embodiment of the present invention, the first and second panels 11, 21 are attached on opposed sides of the insulant panels 31 with adhesives. Alternatively, or additionally, said attachment is obtained or reinforced with screws and / or with nails and / or with spiked elements glued to the first and second panels 11, 21 and inserted into the insulating panels 31.

[0079] The wall assembly can further include a first structural connector 51 on each end of said at least one beam 41, and / or a second structural connector 52 on the upper end and on the lower end of each column 42.

[0080] Those first and / or second structural connectors 51, 52 provide structural connection ports for connecting the wall assembly to other adjacent wall assemblies and / or to structural floor slabs located below or above the wall assembly.

[0081] According to one possible embodiment, each first and / or second structural connector 51, 52 comprises a bolted connector and / or a fitting connector. In this case, each first and / or second structural connector 51, 52 located on one peripheral side of the wall assembly, for example on the left lateral side or on the bottom side, is complementary to a corresponding first and / or second structural connector 51, 52 located on another opposite peripheral side of the wall assembly, for example the right lateral side or the upper side. In this manner, the structural connectors located on one left lateral side of one wall assembly will be complementary and couplable to the structural connectors of the right lateral side of an identical adjacent wall assembly.

[0082] According to another different embodiment, each first and / or second structural connector 51, 52 comprises dowel bars protruding from the inner load bearing structure 40. In this case, each first and / or second structural connector 51, 52 includes a proximal portion contained in a connection cavity 54 defined between the first and second layers 10, 20, on one peripheral side of the wall assembly. Each first and / or second structural connector 51, 52 further includes a distal portion projecting from the wall assembly, not contained in the connection cavity 54, the distal portion of each first and / or second structural connector 51, 52 located on one peripheral side of the wall assembly, for example on the left lateral side or on the bottom side, having a size, shape and position complementary with the connection cavity 54 of the corresponding first and / or second structural connector 51, 52 located on another opposite peripheral side of the wall assembly. In this way, when this wall assembly is positioned adjacent to an identical wall assembly, the distal portions of the structural connectors projecting from one wall assembly can be completely housed and contained within the connection cavity 54 of the adjacent wall assembly, where later can be embedded in poured concrete, using the connection cavity as a lost formwork.

[0083] The wall assembly may further include building services lines and / or ducts 60, for example electric cables, signal cables, water pipes, drainage conduits and / or conduits for cable routing, embedded in the third layer attached to the second layer 20, or inserted in the building utilities channels 80.

[0084] Such building services lines and / or ducts 60 are preferably accessible through access openings 61 of the first layer 10 and / or of the second layer 20. Those access openings 61 can be used, for example, to fit sockets, switches, water supply points or drainage points.

[0085] Each building service line and / or duct 60 will preferably include at least one quick connector 62 on one end thereof housed in a connection housing 63 located in a peripheral region of the wall assembly adjacent to a peripheral edge thereof. The connection housing, located at the peripheral edge of the wall assembly, are dimensioned to contain the quick connectors.

[0086] These quick connectors allow for an easy, fast and reliable connection of the building service lines and / or ducts 60 of one wall assembly with building service lines and / or ducts 60 of adjacent wall assemblies and / or of adjacent floor slabs also containing building service lines and / or ducts embedded therein with complementary quick connectors.

[0087] According to one embodiment, the beam 41 and / or the columns 42 of the inner load bearing structure 40 are separated from the first and / or second layer 10, 20 by portions of the insulant panels 31 with a reduced thickness, providing thermal insulation to the inner load bearing structure 40.

[0088] According to a second aspect, the present invention is directed to a construction method with wall assemblies.

[0089] The proposed method comprises building a wall assembly by forming a first layer 10, forming an intermediate layer 30, by attaching an insulant material to the first layer 10, and forming a second 20 layer attached to the intermediate layer 30.

[0090] The method further comprises forming an inner load bearing structure 40 housed between the first layer 10 and the second layer 20, embedded in the intermediate layer 30, the inner load bearing structure 40 comprising at least one beam 41 extending along the entire longitude of the intermediate layer 30, and multiple parallel columns 42 perpendicular to the beam 41 extending along the entire height of the intermediate layer 30.

[0091] A rigid matrix is formed by the intersection of the columns and said at least one beam.

[0092] The forming of the first layer 10 comprises arranging multiple first panels 11, each of a predefined shape and dimension, coplanar, laterally adjacent to and in contact with each other at their peripheral edges 12 according to a predefined disposition. In this manner, no open gaps but only closed joints are created within the first layer 10 between adjacent first panels 11.

[0093] The forming of the intermediate layer 30 comprises arranging one third layer by arranging multiple insulant panels 31, each of a predefined shape and dimension, coplanar, laterally adjacent to and in contact with each other at their peripheral edges 32 according to a predefined disposition, while attaching the insulant panels 31 over the first layer 10 defining a first assembly. In this manner, no open gaps, but only closed joints, are created within the intermediate layer 30 between adjacent insulant panels 31.

[0094] The third layer is formed ensuring that the peripheral edges 32 of the insulant panels 31 are misaligned with the peripheral edges 12 of the first panels 11, i.e. that no closed joint between two adjacent insulant panels 31 is parallel to and overlaps a closed joint defined between adjacent first panels 11, creating an offset between the closed joints of the first layer 10 and the closed joints of the intermediate layer 30. This ensures that each pair of adjacent first panels 11 are attached to the same insulant panel 31, at least in a region adjacent with the closed joint, where said offset between the closed joints of the first layer and of the intermediate layer 30 ensures that one single insulant panel 31 is at least partially overlapped simultaneously to both adjacent first panels 11 and attached thereto.

[0095] The forming of the inner load bearing structure 40 comprises a first operation of cutting or carving an inner housing 70 on the third layer attached to the first layer 10 of the first assembly.

[0096] The inner housing 70 has a shape and size complementary with the shape and size of the inner load bearing structure 40. Therefore, the inner housing 70 comprises at least one beam channel 71 extending along the entire longitude of the intermediate layer 30, and a plurality of parallel column channels 72, each extending along the entire height of the intermediate layer 30, the at least one beam channel 71 and the column channels 72 intersecting to each other.

[0097] This cutting and / or carving is performed before the formation of the second layer, when one of the two main surfaces of the intermediate layer 30, where the second layer has to be attached, is exposed. In this manner, the cutting and / or carving can be performed on the said exposed main surface of the intermediate layer 30, in an easy, fast and economical manner.

[0098] During a second operation, performed after the first operation, a prefabricated load bearing structure 45 or an inner rebar assembly 46 precursor of the inner load bearing structure 40, is housed within the inner housing 70.

[0099] The inner rebar assembly 46 is a tridimensional mesh of interconnected metallic rebars comprising multiple parallel columns meshes and at least one beam mesh interconnected, the inner rebar assembly 46 having a shape and size complementary with the shape and size of the inner housing 70 where it is inserted.

[0100] The inner rebar assembly 46 is a precursor of the inner load bearing structure 40, which is obtained by embedding the inner rebar assembly 46 in concrete poured and hardened within the inner housing 70 during a third operation.

[0101] According to the above, the inner load bearing structure 40 can be a prefabricated load bearing structure, produced outside the wall, inserted within the inner housing 70 of the first assembly before the assembly of the second layer 20, during the second operation. Preferably, the prefabricated load bearing structure is inserted in the inner housing through the exposed main surface of the intermediate layer 30 where the second layer has to be attached.

[0102] Alternatively, the inner load bearing structure 40 is produced during a third operation of pouring and curing concrete within the inner housing 70 already containing the inner rebar assembly 46. The inner rebar assembly 46 is inserted within the inner housing 70 of the first assembly before the assembly of the second layer 20, during the second operation.

[0103] The third operation can be performed before the assembly of the second layer, for example with the first assembly in horizontal position, after the formation of the second layer and before transporting the wall assembly to the building site or after the formation of the second layer 20 and after transporting the wall assembly to the building site, with the wall assembly in vertical orientation.

[0104] Thus, the forming of the second layer 20 is performed after the second operation of inserting the prefabricated load bearing structure 45 in the inner housing 70, or after the third operation of pouring and curing concrete in the inner housing containing the inner rebar assembly 46, or between the second operation of inserting the inner rebar assembly 46 and the third operation of pouring and curing concrete.

[0105] The forming of the second layer 20 comprises arranging multiple second panels 21, each of a predefined shape and dimension, coplanar, laterally adjacent to and in contact with each other at their peripheral edges 22, misaligning the peripheral edges 22 of the second panels 21 with the peripheral edges 32 of the insulant panels 31, while attaching the second panels 21 over the insulant panels 31.

[0106] Finally, the construction method comprises transporting the wall assembly to a building site after forming the second layer 20, or after forming the second layer 20 and before performing the third operation, the inner housing 70 containing only the inner rebar assembly 46 without concrete. Once in the building site, the method comprises connecting the wall assembly to other adjacent wall assemblies previously produced and perform the third operation if it has not been performed yet.

[0107] The method can optionally comprise arranging an additional third layer, made of multiple insulant panels 31, each of a predefined shape and dimension, coplanar, laterally adjacent to and in contact with each other at their peripheral edges 32 according to a predefined disposition, the additional third layer being overlapped and attached to the previously formed third layer before the formation of the second layer 20, the second layer being formed and attached over said additional third layer.

[0108] This additional third layer covers the inner housing, providing thermal insulation between the inner housing and the second layer 20, preventing thermal bridges of the inner load bearing structure 40.

[0109] According to one embodiment, the inner load bearing structure 40 is separated from the first and / or second layer 10, 20 by portions of the insulant panels 31 with a reduced thickness, providing thermal insulation to the inner load bearing structure 40.

[0110] Preferably, the inner housing is cut or carved in the intermediate layer forming a local reduction in thickness of the intermediate layer, leaving portions of the insulant panels 31 with a reduced thickness between the inner housing 70 and the first layer 10. Optionally, the inner housing 70 of the first assembly can be covered with a thin insulating panel before the assembly of the second layer to create a thermal insulation between the inner housing and the second layer.

[0111] The method may further comprise cutting or carving building utilities channels 80 on the third layer to be attached to the second layer 20, installing building services lines and / or ducts 60 in said building utilities channels 80 before forming the second layer 20, and cutting access openings 61 for building services lines and / or ducts 60 on the first panels 11 before or after forming the first layer 10 and / or on the second panels 21 before or after forming the second layer 20.

[0112] The building services lines and / or ducts 60 may be installed crossing through the column channels 72 and / or through the at least one beam channel 71 of the inner housing 70 before pouring concrete therein, being therefore partially embedded in the concrete, but preferably the building utilities channels 80 are cut or carved completely on the insulant material, crossing the columns and / or the at least one beam of the inner load bearing structure 40 through the insulant material of reduced thickness interposed between the inner load bearing structure 40 and the first layer 10 or the second layer 20.

[0113] The first operation of cutting or carving the intermediate layer may comprise cutting or carving the insulant panels 31 individually before being arranged forming the intermediate layer 30.

[0114] The areas of the intermediate layer to be cut or carved can be signaled by printing, scoring for example with a laser beam, or projecting with a light projector, on the surface of the intermediate layer 30 once assembled, or on the individual insulant panels 31 before the formation of the intermediate layer 30, as an aid for the cutting or carving operations.

[0115] The printing, scoring or projecting will project at least the edges of the areas to be cut or carved during the first operation according to a pattern stored in a digital memory. Then an operator can perform the cutting or carving operation following the aid.

[0116] Similarly, the areas of the first layer 10 or of the second layer 20 to be cut for forming windows, doors and / or access openings 61 can be signaled by printing, scoring for example with a laser beam, or projecting with a light projector, on the surface of the first or second layer 10, 20 once assembled, or on the individual fist panels 11 before the formation of the first layer 10, or on the individual second panels 20 before the formation of the second layer 20, as an aid for the cutting operation.

[0117] Alternatively, the cutting or carving is performed by an automatic robotic arm following a predefined pattern on the intermediate layer 30 once assembled, or on the individual insulant panels 31 before the formation of the intermediate layer 30, on the surface of the first or second layer 10, 20 once assembled, or on the individual fist panels 11 before the formation of the first layer 10, or on the individual second panels 20 before the formation of the second layer 20.

[0118] The third operation of pouring and curing concrete is performed before the formation of the second layer 20 with the first assembly in horizontal position or is performed after the formation of the second layer 20 with the wall assembly in horizontal position or is performed after the formation of the second layer 20 with the wall assembly in vertical position.

[0119] In any case, when the concrete is to be poured within the inner housing 70 with the wall assembly in a horizontal position, the method comprises sealing with a sealing plate 73 all the peripheral openings of the inner housing 70 accessible through all the peripheral sides of the first assembly before performing the third operation, in order to contain the poured concrete within the inner housing.

[0120] Said sealing plates will be perpendicular to the first layer and will be coincident with the edges of the intermediate layer, completely covering any access to the inner housing through the peripheral sides of the first assembly.

[0121] Optionally, when the pouring is to be performed after the assembly of the second layer, with the wall assembly in vertical orientation, the sealing plates can be installed only in all the peripheral openings of the inner housing 70 accessible through the lower and both lateral peripheral sides of the wall assembly, leaving uncovered the openings accessible through the upper peripheral side of the wall assembly. This allows pouring of the concrete through said openings accessible through the upper peripheral side of the wall assembly.

[0122] Optionally, the sealing plates 73 can integrate first and / or second connectors 51, 52.

[0123] In this case, the first structural connector 51 will be included in each sealing plate 73 sealing one opening of the inner housing 70 accessible through lateral peripheral sides of the wall assembly intended to become one end of one beam 41.

[0124] The second structural connector 52 will be included in each sealing plate 73 sealing one opening of the inner housing 70 accessible through the lower peripheral side or through both the lower and the upper peripheral sides of the wall assembly intended to become end of the columns 42.

[0125] The first structural connector 51 may comprise a bolted connector and / or fitting forms, the first structural connector of one end of the at least one beam being complementary to the first connector of the opposed end of the same beam.

[0126] The second structural connector 52 may comprise a bolted connector and / or fitting forms, the second structural connector of the upper end of each column being complementary to the first connector of the lower end of the same column.

Claims

1. Wall assembly comprising: a first layer (10) and a second layer (20), attached to opposed sides of an intermediate layer (30) made of an insulant material; an inner load bearing structure (40) housed between the first layer (10) and the second layer (20), embedded in the intermediate layer (30), the inner load bearing structure (40) comprising at least one beam (41), extending along the entire longitude of the intermediate layer (30), and multiple parallel columns (42) perpendicular to the beam (41) and extending along the entire height of the intermediate layer (30); characterized in that the first layer (10) comprises multiple first panels (11), each of a predefined shape and dimension, arranged coplanar, laterally adjacent to and in contact with each other at their peripheral edges (12), and the second layer (20) comprises multiple second panels (21), each of a predefined shape and dimension, arranged coplanar, laterally adjacent to and in contact with each other at their peripheral edges (22); the intermediate layer (30) comprises one third layer, or two overlapped and attached third layers, each third layer being made of multiple insulant panels (31) arranged coplanar, laterally adjacent to and in contact with each other at their peripheral edges (32), the peripheral edges (32) of the insulant panels (31) being misaligned with the peripheral edges (12, 22) of the first panels (11) and of the second panels (21); and each pair of adjacent first panels (11) are attached to the same insulant panel (31) and each pair of adjacent second panels (21) are attached to the same insulant panel (31).

2. The wall assembly according to claim 1 wherein the first and second panels (11, 21) are attached on opposed sides of the intermediate layer (30) with adhesives and / or with screws and / or with nails and / or with spiked elements glued to the first and second panels (11, 21) and inserted into the insulating panels (31).

3. The wall assembly according to claim 1 or 2 wherein the inner load bearing structure (40) is embedded on the third layer attached to the first layer (10), and another additional third layer is interposed between the inner load bearing structure (40) and the second layer (20) providing thermal insulation to the inner load bearing structure (40).

4. The wall assembly according to claims 1, 2 or 3 wherein the wall assembly further includes a first structural connector (51) on each end of the at least one beam (41), and / or a second structural connector (52) on the upper end and on the lower end of each column (42).

5. The wall assembly of claim 4, wherein each first and / or second structural connector (51, 52) comprises a bolted connector and / or a fitting connector, each first and / or second structural connector (51, 52) located on one peripheral side of the wall assembly being complementary to a corresponding first and / or second structural connector (51, 52) located on another opposite peripheral side of the wall assembly; or each first and / or second structural connector (51, 52) comprises dowel bars protruding from the inner load bearing structure (40), each first and / or second structural connector (51, 52) including a proximal portion contained in a connection cavity (54) defined between the first and second layers (10, 20) on one peripheral side of the wall assembly, and including a distal portion projecting from the wall assembly, the distal portion of each first and / or second structural connector (51, 52) located on one peripheral side of the wall assembly having a size, shape and position complementary with the connection cavity (54) of the corresponding first and / or second structural connector (51, 52) located on another opposite peripheral side of the wall assembly.

6. The wall assembly according to any preceding claim wherein the first and second panels (11, 21) are cementitious panels made of cementitious material or made of cement bonded cellulose fibers; and / or have a thickness comprised between 6mm and 30mm.

7. The wall assembly according to any preceding claim wherein the wall assembly further includes building services lines and / or ducts (60), embedded in the third layer attached to the second layer (20), accessible through access openings (61) of the first layer (10) and / or of the second layer (20).

8. The wall assembly according to claim 8 wherein each building service line and / or duct (60) includes at least one quick connector on one end thereof housed in a connection housing located in a peripheral region of the wall assembly adjacent to a peripheral edge thereof.

9. The wall assembly according to any preceding claim wherein the beam (41) and / or the columns (42) of the inner load bearing structure (40) are separated from the first and / or second layer (10, 20) by portions of the insulant panels (31) with a reduced thickness.

10. Construction method with wall assemblies, the method comprising building a wall assembly by: forming a first layer (10); forming an intermediate layer (30) by attaching an insulant material to the first layer (10); forming a second (20) layer attached to the intermediate layer (30); forming an inner load bearing structure (40) housed between the first layer (10) and the second layer (20), embedded in the intermediate layer (30), the inner load bearing structure (40) comprising at least one beam (41) extending along the entire longitude of the intermediate layer (30), and multiple parallel columns (42) perpendicular to the beam (41) extending along the entire height of the intermediate layer (30); characterized in that: the forming of the first layer (10) comprises arranging multiple first panels (11), each of a predefined shape and dimension, coplanar, laterally adjacent to and in contact with each other at their peripheral edges (12) according to a predefined disposition, the forming of the intermediate layer (30) comprises arranging one third layer by arranging multiple insulant panels (31), each of a predefined shape and dimension, coplanar, laterally adjacent to and in contact with each other at their peripheral edges (32) according to a predefined disposition, misaligning the peripheral edges (32) of the insulant panels (31) with the peripheral edges (12) of the first panels (11), while attaching the insulant panels (31) over the first layer (10) defining a first assembly; the forming of the inner load bearing structure (40) comprises: cutting or carving, during a first operation, an inner housing (70) on the third layer of the first assembly, the inner housing (70) comprising at least one beam channel (71) extending along the entire longitude of the intermediate layer (30), and a plurality of parallel column channels (72), each extending along the entire height of the intermediate layer (30); housing within the inner housing (70), during a second operation, a prefabricated load bearing structure (45) or an inner rebar assembly (46) precursor of the inner load bearing structure (40) to be later embedded in concrete poured and hardened in the inner housing (70) during a third operation; and the forming of the second layer (20) is performed after the second operation or after the third operation or between the second and third operations, and comprises arranging multiple second panels (21), each of a predefined shape and dimension, coplanar, laterally adjacent to and in contact with each other at their peripheral edges (22), misaligning the peripheral edges (22) of the second panels (21) with the peripheral edges (32) of the insulant panels (31) on which the second panels (21) are attached; transporting the wall assembly to a building site after forming the second layer (20) or after forming the second layer (20) and before performing the third operation and connecting the wall assembly to other adjacent wall assemblies.

11. The construction method according to claim 10 wherein, the method comprises, before the formation of the second layer (20), arranging an additional third layer made of multiple insulant panels (31), each of a predefined shape and dimension, coplanar, laterally adjacent to and in contact with each other at their peripheral edges (32) according to a predefined disposition, the additional third layer being overlapped and attached to the third layer of the first assembly, the second layer being formed and attached over said additional third layer.

12. The construction method according to claim 10 or 11 wherein, the method comprises: cutting or carving utilities channels (80) on the third layer to be attached to the second layer, installing building services lines and / or ducts (60) in said building utilities channels (80) before forming the second layer (20); and / or cutting access openings (61) for building services lines and / or ducts (60) on the first panels (11) before or after forming the first layer (10) and / or on the second panels (21) before or after forming the second layer (20); and / or the first operation comprises cutting or carving the insulant panels (31) individually before being arranged forming the third layer.

13. The construction method according to claim 10, 11 or 12 wherein printing, scoring or projecting on the intermediate layer (30) or on the individual insulant panels (31) before the formation of the intermediate layer (30), the areas to be cut or carved during the first operation as an aid for the cutting or carving operation; printing, scoring or projecting on the first layer (10) or on the individual first panels (11) before the formation of the first layer (10), areas to be cut for forming windows, doors and / or access openings (61) as an aid for the cutting operation; printing, scoring or projecting on the second layer (20) or on the individual second panels (21) before the formation of the second layer (20), areas to be cut for forming windows, doors and / or access openings (61) as an aid for the cutting operation.

14. The construction method according to any preceding claim 10 to 13 wherein the third operation is performed before the formation of the second layer (20) with the first assembly in horizontal position or is performed after the formation of the second layer (20) with the wall assembly in horizontal position or is performed after the formation of the second layer (20) with the wall assembly in vertical position.

15. The construction method according to claim 14 wherein before performing the third operation, the method comprises sealing with a sealing plate (73) or with a sealing plate (73) integrating first and / or second structural connectors (51, 52), all the peripheral openings of the inner housing (70) accessible through all the peripheral sides of the wall assembly, or all the peripheral openings of the inner housing (70) accessible through the lower and both lateral peripheral sides of the wall assembly, to contain the concrete in the inner housing (70), wherein the first structural connector (51) is included in each sealing plate (73) sealing one opening of the inner housing (70) intended to become one end of one beam (41) and / or the second structural connector (52) is included in each sealing plate (73) sealing one opening of the inner housing (70) intended to become one end of one column (42).

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