Multi-functional panel system

Abstract

The present disclosure relates to a multi-panel system and a method of producing thereof. The construction element comprises a first panel having a first end and an opposed second end; a second panel spaced apart from the first panel, the second panel having a first end and an opposed second end; a spacing medium placed between the first and second panels, and adhering to each of the first and second panels; and at least one structural member integrally formed in at least one of the panels, and extending from the first end to the second end of the least one panels. At least one structural member is provided for bearing external force, and the first panel does not contact the second panel to prevent thermal bridging.

Description

MULTI-FUNCTIONAL PANEL SYSTEMFIELD

[0001] The present disclosure relates to standalone construction elements for building components to facilitate rapid construction, and in particular to composite panel systems for building a structure without using a pre-installed structural framing.BACKGROUND

[0002] The background herein is included solely to explain the context of the disclosure. This is not to be taken as an admission that any of the material referred to was published, known, or part of the common general knowledge as of the priority date.

[0003] Current building wall construction methods vary depending on factors such as climate, structural requirements, and architectural preferences; however, several common practices have been widely adopted in both residential and commercial building sectors. Typically, exterior wall construction begins with a structural frame, which may be formed from wood studs, steel studs, or concrete masonry units. Wood framing is the predominant method used in low-rise residential construction due to its availability, ease of use, and thermal performance. In contrast, steel stud framing or poured concrete walls are more commonly used in mid-rise and high-rise buildings, as well as in regions requiring enhanced fire resistance or structural integrity.

[0004] Once the framing is in place, the wall assembly is generally sheathed using materials such as plywood, or exterior-grade gypsum board to provide structural rigidity and a substrate for further layers. A weather-resistive barrier, such as house wrap or building paper, is applied over the sheathing to prevent water infiltration while allowing moisture vapor to escape from the interior.

[0005] The final layers of the wall assembly include a cladding material, such as brick veneer, fiber cement board, vinyl siding, or stucco, which serves as the primary defense against environmental exposure. Cladding is typically installed with an air gap or rainscreen system to promote drainage and ventilation behind the exterior surface. On the interior side of the wall, additional insulation may be placed between the studs, followed by a vapor barrier and gypsum drywall to complete the wall assembly.

[0006] In colder regions, wall systems can be designed to include continuous insulation or additional exterior insulation to meet stringent thermal performance standards set forth by provincial or national energy codes. This insulation layer typically comprises rigid foam boards, mineral wool panels, or spray-applied polyurethane foam, and is often installed outside the weather-resistive barrier to minimize thermal bridging.

[0007] Thermal bridging refers to the phenomenon in which heat transfers across a building envelope through materials that are more conductive than the surrounding insulation. In typical wall assemblies, thermal bridges occur at locations where structural elements — such as wood or steel studs — penetrate or bypass insulation layers, creating a path of least resistance for heat flow. Because these framing components generally have significantly higher thermal conductivity than insulation materials, they allow heat to bypass insulated areas and escape to the exterior in cold weather or enter the building during warm weather.

[0008] The presence of thermal bridging in a wall assembly undermines the overall thermal performance of the building envelope. This can result in increased energy consumption for heating and cooling, uneven interior surface temperatures, and occupant discomfort. Additionally, thermal bridging can lead to the formation of cold spots on interior surfaces, which may cause condensation to accumulate. Over time, this trapped moisture can lead to the growth of mold, degradation of building materials, and a reduction in the service life of the wall assembly.SUMMARY

[0009] Present disclosure provides a construction element for various structural systems such as framed, infilled-frame, and wall loadbearing building system to prevent or minimize thermal bridging. The construction elements can bear external force by themselves and can be formed as various elements of a building such as roof, floor, beam, column, beam-column joint, which allows engineers to directly construct a building by simply connecting multiple such construction elements without installing any additional structural framing in advance. Moreover, the construction element can be designed to avoid thermal bridging, and thus save extensive costs on heating and cooling. This construction element will make building construction fast, easy, and inexpensive.

[0010] In at least one aspect of the invention, a construction element is provided herein. The construction element comprises: a first panel having a first end and an opposed second end; a second panel spaced apart from the first panel, the second panel having a first end and an opposed second end; a spacing medium placed between the first and second panels, and adhering to each of the first and second panels; and at least one structural member integrally formed in at least one of the panels, and extending from the first end to the second end of the least one panels. The at least one structural member is provided for bearing external force. The first panel does not contact the second panel to prevent thermal bridging.

[0011] In at least one embodiment, the panels consist of at least one of: metal, alloy, polymer, ceramic, composite material, or a combination thereof.

[0012] In at least one embodiment, the spacing medium consists of at least one of: polymer, composite material, natural product, liquid, gas, or a combination thereof.

[0013] In at least one embodiment, the spacing medium further comprises at least one duct for at least one of: utilities, ventilation, plumbing, electricity, energy, communication, and heating.

[0014] In at least one embodiment, the at least one structural member is at least one of: circular-shaped, rectangular-shaped, and C-shaped.

[0015] In at least one embodiment, the at least one structural member is constructed of at least one of single layer bending or multi-layer bending.

[0016] In at least one embodiment, the C-shaped structural member is at least one of left-facing or right-facing.

[0017] In at least one embodiment, the structural member is manufactured separately from the panel, and later joined using at least one of: clinching, hemming, brazing, soldering, welding, and adhesives.

[0018] In at least one embodiment, the construction element further comprises a beam having a plurality of structural members and a spacing medium placed between the plurality of structural members.

[0019] In at least one embodiment, two or more construction elements are connected to form at least one of: roof, beams, columns, beam-column joint, walls, floor, ceiling, stairs, foundation, exterior decoration, interior decoration, and furniture.

[0020] In at least one aspect of the invention, a construction element is provided herein. In at least one embodiment, the construction element comprises: two or more surfaces, at least one of the surfaces having one or more deformations; and a spacing medium in a space defined by all surfaces; wherein the deformations are structural elements for bearing external force, and wherein one of the surfaces connects with at least one of the remaining surfaces.

[0021] In at least one embodiment, the surfaces comprise metal, alloy, polymer, ceramic, composite material, or a combination thereof.

[0022] In at least one embodiment, the space medium comprises metal, alloy, polymer, ceramic, composite material, natural product, liquid, gas, or a combination thereof.

[0023] In at least one embodiment, the use of the construction element for constructing a structure is provided herein comprising: connecting two or more construction elements without using a pre-installed structural framing, wherein the structure comprises roof, beams, columns, beam-column joint, walls, floor, ceiling, stairs, foundation, exterior decoration, interior decoration, or furniture.

[0024] In at least one aspect of the disclosure, a method of manufacturing a construction element is taught herein. The method comprises the steps of: Preparing a first panel having a first end and an opposed second end; Preparing a second panel spaced apart from the first panel, the second panel having a first end and an opposed second end; Providing a spacing medium placed between the first and second panels, and adhering to each of the first and second panels; and Forming at least one structural member in at least one of the panels, wherein the structural member extends from the first end to the second end of the least one panels.

[0025] In at least one embodiment, the method further comprises: constructing the panels of at least one of: metal, alloy, polymer, ceramic, composite material, or a combination thereof.

[0026] In at least one embodiment, the method further comprises: constructing the spacing medium of at least one of: polymer, composite material, natural product, liquid, gas, or a combination thereof.

[0027] In at least one embodiment, the method further comprises: constructing at least one duct in the spacing medium for at least one of: utilities, ventilation, plumbing, electricity, energy, communication, and heating.

[0028] In at least one embodiment, the at least one structural member is constructed by bending the panel into a shape.

[0029] In at least one embodiment, the structural member is manufactured separately from the panel, and further comprising joining the structural member to the panel using at least one of: clinching, hemming, brazing, soldering, welding, and adhesives.

[0030] Accordingly, in an aspect of the present disclosure, the construction element comprises two or more surfaces, and at least one of the surfaces has one or more deformations. A spacing medium adheres to each surface. The deformations are structural elements for bearing external force, and each surface does not contact with remaining surfaces to prevent thermal bridging.

[0031] In some embodiments, the surfaces comprise metal, alloy, polymer, ceramic, composite material, or a combination thereof.

[0032] In some embodiments, the spacing medium comprises polymer, composite material, natural product, liquid, gas, or a combination thereof.

[0033] In some embodiments, the spacing medium can incorporate ducts for utilities comprising ventilation, plumbing, electricity, energy, communication, or heating.

[0034] According to another aspect of the present disclosure, the construction element comprises two or more surfaces, and at least one of the surfaces has one or more deformations. A space medium is in a space defined by all surfaces. The deformations arestructural elements for bearing external force, and one of the surfaces connects with at least one of the remaining surfaces.

[0035] In some embodiments, the surfaces comprise metal, alloy, polymer, ceramic, composite material, or a combination thereof.

[0036] In some embodiments, the space medium comprises metal, alloy, polymer, ceramic, composite material, natural product, liquid, gas, or a combination thereof.

[0037] According to another aspect of the present disclosure, a structure can be constructed by connecting two or more construction elements without using a pre-installed structural framing, wherein the structure comprises roof, beams, columns, beam-column joint, walls, floor, ceiling, stairs, foundation, exterior decoration, interior decoration, or furniture.

[0038] Other features and advantages of the present disclosure will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating embodiments of the disclosure, are given by way of illustration only and the scope of the claims should not be limited by these embodiments, but should be given the broadest interpretation consistent with the description as a whole.DRAWINGS

[0039] Certain embodiments of the disclosure will now be described in greater detail with reference to the attached drawings in which:

[0040] FIG. 1A is a plan view of the construction element for use as a panel in exemplary embodiments of the disclosure.

[0041] FIG. 1 B is a perspective view of the construction element for use as a panel in exemplary embodiments of the disclosure.

[0042] FIG. 2A is a plan view of plurality of formed structural members integrally formed on a surface of the construction element in exemplary embodiments of the disclosure.structural elements for bearing external force, and one of the surfaces connects with at least one of the remaining surfaces.

[0035] In some embodiments, the surfaces comprise metal, alloy, polymer, ceramic, composite material, or a combination thereof.

[0036] In some embodiments, the space medium comprises metal, alloy, polymer, ceramic, composite material, natural product, liquid, gas, or a combination thereof.

[0037] According to another aspect of the present disclosure, a structure can be constructed by connecting two or more construction elements without using a pre-installed structural framing, wherein the structure comprises roof, beams, columns, beam-column joint, walls, floor, ceiling, stairs, foundation, exterior decoration, interior decoration, or furniture.

[0038] Other features and advantages of the present disclosure will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating embodiments of the disclosure, are given by way of illustration only and the scope of the claims should not be limited by these embodiments, but should be given the broadest interpretation consistent with the description as a whole.DRAWINGS

[0039] Certain embodiments of the disclosure will now be described in greater detail with reference to the attached drawings in which:

[0040] FIG. 1A is a plan view of the construction element for use as a panel in exemplary embodiments of the disclosure.

[0041] FIG. 2B is a perspective view of the construction element for use as a panel in exemplary embodiments of the disclosure.

[0042] FIG. 2A is a plan view of plurality of formed structural members integrally formed on a surface of the construction element in exemplary embodiments of the disclosure.

[0043] FIG. 2B is a perspective view of plurality of structural members integrally formed on a surface of the construction element in exemplary embodiments of the disclosure.

[0044] FIG. 3A is a plan view of the construction element for use as a panel in exemplary embodiments of the disclosure.

[0045] FIG. 3B is a perspective view of the construction element for use as a panel in exemplary embodiments of the disclosure.

[0046] FIG. 4A is a plan view of the construction element for use as a panel in exemplary embodiments of the disclosure.

[0047] FIG. 4B is a perspective view showing thr construction element for use as a panel in exemplary embodiments of the disclosure.

[0048] FIG. 5A is a plan view of a plurality of construction elements to create a multi-panel system in exemplary embodiments of the disclosure.

[0049] FIG. 5B is a perspective view showing a plurality of construction elements to create a multi-panel system in exemplary embodiments of the disclosure.

[0050] FIG. 6 is a perspective view of an upper and a lower track on a structure formed by plurality of construction elements to create a multi-panel system in exemplary embodiments of the disclosure.

[0051] FIG. 7 is a perspective view of a wall panel, a roof panel and a floor panel formed by using a plurality of construction elements to create a multi-panel system in exemplary embodiments of the disclosure.

[0052] FIG. 8 is a perspective view of ventilation ducts for utilities in the insulation of a construction element for to create a multi-panel system in exemplary embodiments of the disclosure.

[0053] FIG. 9 is a perspective view of a plurality of construction elements and their surfaces for use as a column and a beam in exemplary embodiments of the disclosure.

[0054] FIG. 10 is an elevation view and corresponding cross-sectional views of a structure formed by connecting a plurality of construction elements in exemplary embodiments of the disclosure.

[0055] FIG. 11 is an exploded perspective view of a plurality of construction elements to create a multi-panel system in exemplary embodiments of the disclosure.

[0056] FIG. 12 is a perspective view of the multi-panel system, in an exemplary embodiment of the disclosure.

[0057] FIG. 13 is an elevation view and corresponding cross-sectional views of two panels being connected to form a wall, floor, or ceiling, in an exemplary embodiment of the disclosure.

[0058] FIG. 14 is an elevation view and corresponding cross-sectional views of the panelized system having a window opening, in an exemplary embodiment of the disclosure.DETAILED DESCRIPTION

[0059] Unless otherwise indicated, the definitions and embodiments described in this and other sections are intended to be applicable to all embodiments and aspects of the present disclosure herein described for which they are suitable as would be understood by a person skilled in the art. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

[0060] In understanding the scope of the present disclosure, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and / or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and / or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. The term “consisting” and its derivatives, as used herein, are intended to be closed terms that specify the presence of the stated features, elements, components, groups, integers, and / or steps, but exclude the presence of other unstated features, elements, components, groups, integers and / or steps. The term“consisting essentially of’, as used herein, is intended to specify the presence of the stated features, elements, components, groups, integers, and / or steps as well as those that do not materially affect the basic and novel characteristic(s) of features, elements, components, groups, integers, and / or steps.

[0061] Terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree should be construed as including a deviation of at least ±5% of the modified term if this deviation would not negate the meaning of the word it modifies. In addition, all ranges given herein include the end of the ranges and also any intermediate range points, whether explicitly stated or not.

[0062] As used in this disclosure, the singular forms “a”, “an” and “the” include plural references unless the content clearly dictates otherwise.

[0063] In embodiments comprising an “additional” or “second” component, the second component as used herein is chemically different from the other components or first component. A “third” component is different from the other, first, and second components, and further enumerated or “additional” components are similarly different.

[0064] The term “and / or” as used herein means that the listed items are present, or used, individually or in combination. In effect, this term means that “at least one of” or “one or more” of the listed items is used or present.

[0065] The abbreviation, “e.g.” is derived from the Latin exempli gratia and is used herein to indicate a non-limiting example. Thus, the abbreviation “e.g.” is synonymous with the term “for example.” The word “or” is intended to include “and” unless the context clearly indicates otherwise.

[0066] It will be understood that any component defined herein as being included may be explicitly excluded by way of proviso or negative limitation, such as any specific compounds or method steps, whether implicitly or explicitly defined herein.

[0067] The present disclosure relates to an integrated multi-functional composite panel that can be shaped into different building components to facilitate rapid construction,and in particular, to standalone construction elements for building a structure without using a pre-installed structural framing.

[0068] The current North American Standards for cold-formed steel (AISI S100-20) allows structural studs, with cross sectional shapes meeting specific criteria, to carry gravity load provided they are either braced or sheathed with both sheathing and bracing straps / members connected by welds or screws. Following the construction of the studs, the structural components require external cladding, vapor and air barriers, as well as water and thermal insulation layers and internal finish. The different material and multiple ‘layering’ steps that require extensive skilled labor increase the cost of the resulting construction significantly (for material and labor cost and extensive time for completion) making cold-formed steel less than ideal for mainstream proliferation within general construction.

[0069] The disclosure provided herein adopts the specifications of the AISI S100- 20 standards for typical cold-formed steel stud wall (for gravity load bearing), while integrating the structural studs as a piece of the multi-functional panel following standard manufacturing of insulated metal / steel panel. Whereas the latter has been used for industrial facility wall cladding and roofing, the disclosure provided herein integrates structural elements (such as studs, or joists) within panels, allowing the panels to form a pre-engineered system that will save labor, material, time and cost for construction projects.

[0070] Furthermore, because of the thickness of the panels, the panels can be used to provide wind / hurricane resistance, flood resistance, fire resistance, and the like. The resulting climate resilient, passive construction system can be an appealing solution, especially considering its low cost.

[0071] In at least one aspect of the disclosure, a construction element is provided herein. The construction element refers to a component of the multi-panel system that can be used as paneling in a building / construction project. The construction element proposed herein can be used for interior buildings, exterior buildings, interior walls, exterior walls, floor paneling, ceiling paneling, roof paneling, and the like.

[0072] In at least one embodiment, the construction element comprises: a first panel having a first end and an opposed second end; a second panel spaced apart from the first panel, the second panel having a first end and an opposed second end; a spacing medium placed between the first and second panels, and adhering to each of the first and second panels; and at least one structural member integrally formed in at least one of the panels, and extending from the first end to the second end of the least one panels. The at least one structural member is provided for bearing external force. The first panel does not contact the second panel to prevent thermal bridging.

[0073] Turning now to FIGs. 1 A and 1 B, a plan view, and a perspective view of the construction element 100 for use as a panel is shown therein, respectively. The construction element 100 consists of a first panel 102 and a second panel 104 that face each other and are separated at a distance equal to the element thickness. The panels 102 and 104 can be of any width, thickness, and height. In at least one embodiment, the first panel 102 and second panel 104 are the same width and height. In at least one embodiment, the first panel 102 and second panel 104 are the same thickness. Each of the panels has a first end and an opposed second end. For example, the first end 106 of the second panel 104 is at the top of the panel, and the second end 108 of the second panel 104 is at the bottom of the panel shown in FIG. 1 B.

[0074] FIG. 2A provides a plan view of a plurality of integrally formed structural members. FIG. 2B provides a perspective view of the plurality of integrally formed structural members 202-212. In at least one embodiment, the first and / or second panels can further comprise an inner surface upon which at least one structural member 202-212 can be integrally formed. The structural member 202-212 can extend from the first end of the panel 106 to the second end of the panel 108, such that in the orientation shown in FIG. 2B, the structural member is vertically oriented. As such, the at least one structural member is provided for bearing external force, and acts like a stud. The structural members can be formed by bending the panel material into a desired shape, such as by stamping or deforming.

[0075] The structural member can have any shape, a variety of which can be seen in FIG. 2A. Structural member 202 can be created by bending a single layer panel materialinto a left-facing C-shaped member, with a protrusion to create a left-facing C. In at least one embodiment, the left-facing C-shaped member can be used for edges of the panel, specifically left-most edges of the panel. Structural member 204 can be created by bending a double layer panel material into a left-facing C-shaped member, with an inner layer, and an outer layer added for further reinforcement. Structural member 206 can be created by bending a single layer panel material into a rectangular-shaped member, with an opening directly in the center of the rectangle. Structural member 208 can be created by bending a single layer panel material into a rectangular-shaped member, with an opening in the edge of the rectangle. The opening of the rectangle can alternatively be placed anywhere along the edge of the rectangle. Structural member 210 can be created by bending a single layer panel material into a circular-shaped member, with an opening directly in the center of the circular profile. Structural member 212 can be created by bending a single layer panel material into a right-facing C-shaped member. In at least one embodiment, the right-facing C-shaped member can be used for edges of the panel, specifically right-most edges of the panel.

[0076] The structural members can be made with any material that can be bent or deformed to include any number of members per panel. Each panel can include members that are the same shape, or any combination of shapes thereof. The structural members can be provided to increase the panel's strength and stiffness and to satisfy structural, architectural, and service requirements.

[0077] The structural members 202-212 can extend from the first end of the panel 106 to the second end of the panel 108, such that in the orientation shown in FIG. 2B, the structural member is vertically oriented. As such, the at least one structural member is provided for bearing external force, and acts like a stud. In the embodiment where the panel is used as a floor panel or ceiling panel, the structural member acts like a joist. The structural members can be spaced apart according to building codes and specifications, such as, for example, but not limited to, 12 inches apart, 16 inches apart, 18 inches apart, or 24 inches apart. The structural members can be made on one surface or both surfaces and can be located at the ends of panel surfaces or any other place within the panel surfaces.

[0078] Turning now to FIG. 3A and FIG. 3B, which provide a plan view, and perspective view of the construction element for use as a panel, respectively. In this embodiment, a first structural member 208 is made on the first panel 102, and a second and third structural member 202 and 212 are formed at the ends of the second panel 104.

[0079] If the panel material is steel for example, the steel sheet used is typically treated against corrosion and finished using coating paints or other surface treatments. Prior to applying a final finishing coat, the interior surfaces of the panels can undergo a cold-forming deformation process to create or form the load-bearing structural members within one or both of the panels.

[0080] On the other hand, if the panel material is polymer for example, the external faces of the polymer panel layer can be finished using coating paints or other surface treatments. The load-bearing structural members can be created or formed within one or both of the panels through extrusion or, if fiber-reinforced, through pultrusion processes.

[0081] In at least one embodiment, the structural member can be formed using the same material, such as steel / metal sheet. In this embodiment, the structural member can be made of a single layer or multiple sheet layers (e.g., through multiple bends) if the latter is needed to increase the stud strength / stiffness. In this case, the structural member is integrally formed as a part of the panel material and the structural member would not need to be separately manufactured, and later joined to the panel sheet.

[0082] In at least one embodiment, the panel sheet can be manufactured separately from the structural member, and then later joined to form the integrated steel part of the panel before the spacing medium (or core material) is introduced. The joining of the structural member to panel can be completed through processes including but not limited to metal: clinching, hemming, brazing, soldering, welding, or adhesives. An example of this is shown in FIGs. 12, 13 and 14. In at least one embodiment, the panels can then undergo a continuous or intermittent process to introduce the foam / core material sandwiches or layered between at least two panels.

[0083] FIGs. 4A and 4B provide a plan view, and perspective view of a construction element for use as a panel, respectively. In the embodiment shown in FIGs. 4A and 4B, a core material 402 is provided between the first panel 102 and the second panel 104.

[0084] The construction element 400 can be constructed by combining two panels with a core material 402 (e.g., via adhesives). The core material 402 filling the space between the two panels can be, for example, made of foam insulation, such as polyurethane or polystyrene foam, which helps create an airtight seal around the interior of the building and link the two inner surfaces of the first and second panels to form one multifunctional composite construction element 400. Additionally, an adhesive such as acrylic caulk may be applied to help ensure a proper seal between the adjacent surfaces and between the surfaces and the core material. The first and second panels’ inner surfaces can adhere to an insulation (for example, closed-cell polyurethane) which can be filled into the space between the panels. Since the panels’ inner surfaces are not touching, with insulation in between, the panel provides a zero-thermal bridging system.

[0085] Referring now to FIG. 5A and 5B, which provide a plan view, and perspective view of a plurality of construction elements to create a multi-panel system 500. In at least one embodiment, the edges of each panel can include an interlocking mechanism 504 to hold multiple panels together. Fasteners (e.g. adhesives, screws, and bolts) 502 can be used to fasten multiple panels together. The fastening can improve the structural integrity of a group of panels. By using fasteners 502 between the panels, the diagonal tension / compression forces produced by lateral loads can be transferred through the panels.

[0086] FIG. 6 provides a perspective view of an upper track 602 and a lower track 604 on a multi-panel system in exemplary embodiments of the disclosure. The structural members 208 can be used as studs that can carry structural stresses. Moreover, the upper and lower tracks 602, 604 can be attached to the multi-panel system at the top and bottom edges of the panels.

[0087] FIG. 7 provides a perspective view of a wall panel, a roof panel and a floor panel formed by using a plurality of construction elements for use as panels in exemplary embodiments of the disclosure. As shown in FIG. 7, the multi-panel system can be used for other building components such as walls, typical floors, roofs, and bottom floor systems. The structural members 208 in the floor / ceiling / roof panels work as joists, while the structural members 208 in the wall panels work as studs. The floor / ceiling / roof panels canbe carried on the wall panels where the floor / ceiling / roof panels' structural members (joists) are rested on and connected to the wall panels' structural members (studs).

[0088] In at least one embodiment, the construction element can include carved portions which form ventilation ducts for utilities in the insulation / core material of the construction element 800. An example of the ventilation ducts can be seen in FIG. 8, which shows a panel 102 including ducts 802 for utilities such as ventilation, plumbing, electrical, communication, energy, or other services. The ducts can be provided within the core material 402, which can be carved, or otherwise cut from the core material.

[0089] FIG. 9 shows a perspective view of a plurality of construction elements for use as a column and a beam in exemplary embodiments of the disclosure. Other elements, such as columns 900 and beams 902, could also be manufactured by in a similar way as the panels. The columns 900 and beams 902 are construction elements that consist of separated surfaces with structural members 906. An insulation or core material 402 can be added to the surfaces to form columns 900 and beams 902 with zero-thermal bridging.

[0090] FIG. 10 provides an elevation view and corresponding cross-sectional views of a structure formed by connecting a plurality of construction elements in exemplary embodiments of the disclosure. In this embodiment, panels 1006 and fastened together by fasteners 1002. Columns 1004 can be attached to either side of the panels 1006. An upper beam 1008 can be attached to the top of the panels 1006. A lower beam 1010 can be attached to the bottom of the panels 1006. By fastening the panels’ upper and lower edges with upper and lower beams 1008, 1010, and fastening the end of panels 1006 with columns 1004, and connecting the columns and beams with fasteners 1002, the constructed system acts as a infilled frame structure that can resist loads and have zerothermal bridging properties.

[0091] FIG. 11 provides an exploded perspective view of a plurality of construction elements in exemplary embodiments of the disclosure. In this embodiment, panels 1006 and fastened together by fasteners, columns 900 can be attached to either side of the panels 1006. An upper beam 902 can be attached to the top of the panels 1006. A lower beam 902 can be attached to the bottom of the panels 1006.

[0092] FIG. 12 provides a perspective view of the system, in an exemplary embodiment of the disclosure. In this embodiment, the first panel 102 is provided with a structural member 202 on either end of the panel 102. The second panel 104 is provided with structural members 202 on either end of the panel 104, as well as structural panels 208 provided within the second panel 104.

[0093] FIG. 13 provides an elevation view and corresponding cross-sectional views of two panels being connected to form a wall, floor, or ceiling, in an exemplary embodiment of the disclosure. In this embodiment, the panel sheet was manufactured separately from the structural member, and then later joined to form the integrated steel part of the panel before the foam (or the core material) is introduced. The joining of the structural member to panel can be completed through processes including but not limited to metal: clinching, hemming, brazing, soldering, welding, or adhesives. In at least one embodiment, metal mechanical fasteners (screws, bolts, rivets) can be used.

[0094] FIG. 14 is an elevation view and corresponding cross-sectional views of the panelized system having a window opening, in an exemplary embodiment of the disclosure. The window 1402 may be reinforced with additional structural members and beams 902 as per the design standards / strength / mechanics requirements. The same can be done when a door opening needs to be incorporated in the panel system.

[0095] By eliminating the layer-by-layer conventional construction technique and shifting the paradigm from on-site labor-intensive construction to off-site automated manufacturing, the use of the proposed system enables rapid building construction at a reduced cost. The ease of installation also enables non-skilled labor to construct major parts or entire structures as a do-it-yourself project. The ability to utilize the wall panels, through connecting to the beams and columns, as an infill wall, provide added stiffness and strength to the system, which can eliminate the need for additional bracing. Finally, the zero-thermal bridging properties enables reduced life cycle costs of the structures as it can reduced heating and cooling costs. Additionally, such a building constructed using a multipanel system can achieve zero construction waste and the panels can be deconstructed and reused, making the system recyclable.

[0096] While the present disclosure has been described with reference to examples, it is to be understood that the scope of the claims should not be limited by the embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

[0097] All publications, patents and patent applications are herein incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety. Where a term in the present disclosure is found to be defined differently in a document incorporated herein by reference, the definition provided herein is to serve as the definition for the term.

Claims

Claims:1 . A construction element comprising: a first panel having a first end and an opposed second end; a second panel spaced apart from the first panel, the second panel having a first end and an opposed second end; a spacing medium placed between the first and second panels, and adhering to each of the first and second panels; and at least one structural member integrally formed in at least one of the panels, and extending from the first end to the second end of the least one panels; wherein the at least one structural member is provided for bearing external force, and wherein the first panel does not contact the second panel to prevent thermal bridging.

2. The construction element of claim 1 , wherein the panels consist of at least one of: metal, alloy, polymer, ceramic, composite material, or a combination thereof.

3. The construction element of claim 1 , wherein the spacing medium consists of at least one of: polymer, composite material, natural product, liquid, gas, or a combination thereof.

4. The construction element of claim 1 , wherein the spacing medium further comprises at least one duct for at least one of: utilities, ventilation, plumbing, electricity, energy, communication, and heating.

5. The construction element of claim 1 , wherein the at least one structural member is at least one of: circular-shaped, rectangular-shaped, and C-shaped.

6. The construction element of claim 1 , wherein the at least one structural member is constructed of at least one of single layer bending or multi-layer bending.

7. The construction element of claim 5, wherein the C-shaped structural member is at least one of left-facing or right-facing.

8. The construction element of claim 1 , wherein the structural member is manufactured separately from the panel, and later joined using at least one of: clinching, hemming, brazing, soldering, welding, and adhesives.

9. The construction element of claim 1 , further comprising forming a beam having a plurality of structural members and a spacing medium placed between the plurality of structural members.

10. The construction element of claim 1 , wherein two or more construction elements are connected to form at least one of: roof, beams, columns, beam-column joint, walls, floor, ceiling, stairs, foundation, exterior decoration, interior decoration, and furniture.

11. A construction element, comprising: two or more surfaces, at least one of the surfaces having one or more deformations; and a spacing medium in a space defined by all surfaces; wherein the deformations are structural elements for bearing external force, and wherein one of the surfaces connects with at least one of the remaining surfaces.

12. The construction element of claim 11 , wherein the surfaces comprise metal, alloy, polymer, ceramic, composite material, or a combination thereof.

13. The construction element of claim 11 , wherein the space medium comprises metal, alloy, polymer, ceramic, composite material, natural product, liquid, gas, or a combination thereof.

14. The use of any one of claims 1 -13 for constructing a structure by connecting two or more construction elements without using a pre-installed structural framing, whereinthe structure comprises roof, beams, columns, beam-column joint, walls, floor, ceiling, stairs, foundation, exterior decoration, interior decoration, or furniture.

15. A method of manufacturing a construction element, the method comprising:Preparing a first panel having a first end and an opposed second end;Preparing a second panel spaced apart from the first panel, the second panel having a first end and an opposed second end; andProviding a spacing medium placed between the first and second panels, and adhering to each of the first and second panels; andForming at least one structural member in at least one of the panels, wherein the structural member extends from the first end to the second end of the least one panels.

16. The method of claim 15, further comprising constructing the panels of at least one of: metal, alloy, polymer, ceramic, composite material, or a combination thereof.

17. The method of claim 15, further comprising constructing the spacing medium of at least one of: polymer, composite material, natural product, liquid, gas, or a combination thereof.

18. The method of claim 15, further comprising constructing at least one duct in the spacing medium for at least one of: utilities, ventilation, plumbing, electricity, energy, communication, and heating.

19. The method of claim 15, wherein the at least one structural member is constructed by bending the panel into a shape.

20. The method of claim 15, wherein the structural member is manufactured separately from the panel, and further comprising joining the structural member to the panel using at least one of: clinching, hemming, brazing, soldering, welding, and adhesives.

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