Composite panel, composite wall system and method of installation of the composite panel
Patent Information
- Application Number
- PCT/IN2026/050308
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2025-02-24
- Filing Date
- 2026-02-20
- Publication Date
- 2026-08-27
Smart Images
Figure IN2026050308_27082026_PF_FP_ABST
Abstract
Description
[0001] COMPOSITE PANEL, COMPOSITE WALL SYSTEM AND METHOD OF INSTALLATION OF THE COMPOSITE PANEL
[0002] TECHNICAL FIELD
[0003]
[0001] The present disclosure relates to the field of a construction panel, in particular, to a prefabricated wall panel for a building. Particularly, the present disclosure relates to a prefabricated composite wall panel for the building that sandwiches different materials and is advantageously modular.
[0004] BACKGROUND
[0005]
[0002] The information in this section merely provides background information related to the present disclosure and may not constitute prior art(s) for the present disclosure.
[0006]
[0003] Sandwich exterior wall panels are composite building materials that are commonly used in construction and provide thermal insulation, structural integrity, and aesthetic appeal. The sandwich exterior wall panels typically consist of two layers made from materials, for example, metal, fiber-reinforced plastic, glass, gypsum boards, etc., with a core material in between, such as polyurethane, polystyrene, or mineral wool. The core material provides excellent thermal insulation, helping to maintain energy efficiency in buildings. Said sandwich exterior wall panels may be utilized in a variety of applications, including industrial buildings (such as warehouses, factories, and distribution centers), commercial buildings (such as retail spaces and office complexes) and residential projects (for example, prefabricated homes, etc.).
[0007]
[0004] However, currently known sandwich wall panels are based on load-bearing structures, thereby leading to bulkier framing and designs, and thus necessitating more material usage. Said wall panels are fully surrounded with exposed metal frames which does not give aesthetic appeal to buildings installed with such wall panels. Moreover, the exposed metal frames in both the exterior and interior sides of the wall panels cause the metal frames to absorb more heat, thereby leading to thermal bridging.
[0008]
[0005] Further, the known wall panels are required to be assembled onsite in the building, which leads to a significant increase in on-site assembly effort and time during installation. Also, onsite assembly of the wall panels is cumbersome and possess difficulties in the installation, which at times become hazardous in the case of tall constructions for finishing exteriors. Because the known wall panels are not prefabricated, assembling the wall panels increase the construction workload and time,thereby reducing the efficiency during the site installation. Patent document no. CN106193492A (hereinafter referred to as “CN’492” document) discloses an indoor decorative composite panel comprising a glass fiber layer, an insulation layer and a gypsum layer, in which the insulation layer is provided between the glass fiber layer and the gypsum layer. According to the CN’492 document, the glass fiber layer and the gypsum layer have the same thickness. Further, the thickness of the glass fiber layer is 1 / 3 to 1 / 5 of the thickness of the heat insulating layer. However, the CN’492 document does not discuss regarding the provisions for mounting the composite panel on the walls.
[0009]
[0006] Accordingly, there remains a need in the domain for an improved prefabricated wall panel for an exterior of a building, in which the wall panel overcomes at least the problems and shortcomings identified above.
[0010] SUMMARY
[0011]
[0007] The one or more shortcomings of the prior art are overcome by the system / assembly / method as claimed, and additional advantages are provided through the provision of the system / assembly / method as claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.
[0012]
[0008] Pursuant to an aspect of the present disclosure, in an embodiment, a composite panel is disclosed. The composite panel comprises a frame structure. The frame structure comprises an upper frame member having at least two upper compartments formed at an internal side thereof. The frame structure further comprises a lower frame member having at least two lower compartments formed at an internal side thereof, and at least one panel mating provision at an external side thereof. The frame structure furthermore comprises a first side frame member, and a second side frame member. Each of the first side frame member and the second side frame member comprise coupling provisions that facilitate coupling the composite panel to an adjacent composite panel. The composite panel further comprises a decorative member secured between a frontmost upper compartment of the at least two upper compartments and a frontmost lower compartment of the at least two lower compartments. The composite panel furthermore comprises at least one board coupled to a rearmost uppercompartment of the at least two upper compartments and a rearmost lower compartment of the at least two lower compartments.
[0013]
[0009] In another non-limiting embodiment of the present disclosure, the at least one panel mating provision of the lower frame member comprises connector pins. Each connector pin is adapted to press-fit into a corresponding hole defined in an external body for coupling the composite panel to the external body.
[0014]
[0010] In another non-limiting embodiment of the present disclosure, the at least one panel mating provision of the lower frame member comprises a guide rail. The guide rail is configured to engage with a complimentary-shaped guide rail defined in an external body for coupling the composite panel to the external body. The guide rail is further configured to facilitate a sliding movement of the composite panel on the external body.
[0015] [OH] In another non-limiting embodiment of the present disclosure, the at least one panel mating provision of the lower frame member facilitates locking the composite panel with the external body, upon an angular movement of the composite panel from an inclined position to an upright position.
[0016]
[0012] In another non-limiting embodiment of the present disclosure, the coupling provisions of the first side frame member comprises one or more snap-fit male connectors along a length of the first side frame member. The one or more snap-fit male connectors of the first side frame member is configured to facilitate coupling with a corresponding snap-fit female connector on a second side frame member of the adjacent composite panel.
[0017]
[0013] In another non-limiting embodiment of the present disclosure, the coupling provisions of the second side frame member comprises one or more snap-fit female connectors along a length of the second side frame member. The one or more snap-fit female connectors of the second side frame member is configured to facilitate coupling with a corresponding snap-fit male connector on a first side frame member of the adjacent composite panel.
[0018]
[0014] In another non-limiting embodiment of the present disclosure, the upper frame member, at an external side thereof, defines fastening holes that facilitate fastening the composite panel to an external body.
[0019]
[0015] In another non-limiting embodiment of the present disclosure, the at least one board comprises a first board, and a second board coupled to the first board.
[0016] In another non-limiting embodiment of the present disclosure, the decorative member is secured with the upper frame member and the lower frame member by a sealant.
[0020]
[0017] In another non-limiting embodiment of the present disclosure, the at least one board is plasterboard, cement board, magnesium oxide board, cardboard, wood-based boards, fiber reinforced composites, or wood fiber boards.
[0021]
[0018] In another non-limiting embodiment of the present disclosure, the decorative member is made of glass, photovoltaic panels, aluminum-based composite panels, exterior grade wall linings, gypsum-based boards, cement-based boards, textile reinforced concrete panels, and exterior grade laminated panels.
[0022]
[0019] In another non-limiting embodiment of the present disclosure, the composite panel optionally comprises an insulation material provided between the decorative member and the at least one board.
[0023]
[0020] In another non-limiting embodiment of the present disclosure, the insulation material comprises mineral wool, glass wool, fiberglass, blown-in insulation, expanded polystyrene (EPS), extruded polystyrene (XPS), or polyurethane foam.
[0024]
[0021] In another non-limiting embodiment of the present disclosure, the frame structure is made of aluminum, GI steel or uPVC.
[0025]
[0022] Pursuant to another aspect of the present disclosure, in an embodiment, a composite wall system is disclosed. The composite wall system comprises a first spandrel adapted to be coupled to a floor of a building, and a second spandrel adapted to be coupled to a ceiling of the building. The composite wall system further comprises the composite panel as discussed above. The composite panel is adapted to couple with the first spandrel and the second spandrel. The first spandrel comprises at least one spandrel mating provision that is adapted to engage with the at least one panel mating provision of the composite panel for coupling the composite panel to the first spandrel. The second spandrel defines a plurality of fastening holes that facilitate fastening the composite panel to the second spandrel.
[0026]
[0023] In another non-limiting embodiment of the present disclosure, the at least one spandrel mating provision of the first spandrel comprises spandrel holes. Each spandrel hole is adapted to receive a corresponding connector pin of the lower frame member of the composite panel for press-fitting the composite panel into the first spandrel.
[0027]
[0024] In another non-limiting embodiment of the present disclosure, the at least one spandrel mating provision of the first spandrel comprises a spandrel guide rail that isconfigured to receive and engage with the guide rail of the lower frame member of the composite panel for coupling the composite panel to the first spandrel.
[0028]
[0025] In another non-limiting embodiment of the present disclosure, the at least one panel mating provision of the lower frame member facilitates locking the composite panel with the at least one spandrel mating provision of the first spandrel, upon an angular movement of the composite panel from an inclined position to an upright position.
[0029]
[0026] In another non-limiting embodiment of the present disclosure, the first spandrel and the second spandrel comprise fastening holes adapted to receive fasteners for coupling the first spandrel and the second spandrel to the floor and the ceiling, respectively.
[0030]
[0027] Pursuant to yet another aspect of the present disclosure, in an embodiment, a method of installation of the composite panel is disclosed. The method comprises positioning the at least one panel mating provision of the lower frame member of the composite panel with at least one spandrel mating provision of a first spandrel. The method further comprises angularly moving the lower frame member from an inclined position to an upright position such that the at least one panel mating provision of the lower frame member locks with the at least one spandrel mating provision of the first spandrel. The method furthermore comprises coupling the upper frame member of the composite panel to a second spandrel.
[0031]
[0028] Within the scope of the present disclosure, the composite panel and the composite wall system of the present disclosure provide a modular system for connecting the spandrel or the external body and the composite panel. Further, the panel mating provisions of the lower frame member of the composite panel (i.e., tilt and lock functionality of the lower frame member) allow easy and quick installation of the modular system. Moreover, unitised composite panel comprising glass, insulation and gypsum boards into a single modular unit reduces inventory demand during installation. Also, the composite panel facilitates installation of the unitized composite panel from the inside of the building without the use of external help like cranes, lifting equipment, scaffolding etc. Additionally, owing to the structural configuration of the composite panel, no assembly of components is required, thus leading to zero assembly time of the composite panel onsite, for installation.
[0032]
[0029] In accordance with the present disclosure, the composite panel and the composite wall system provide non-load bearing units / system, thereby leading to lessmaterial usage. Further, the gypsum boards in the composite panel improve the perception for the residential users, by providing visual privacy (opaqueness) and ambience of a residential area. Also, the modular composite wall system provides freedom to the residential user for setting up the residential areas as well as the external system as per choice, for example, changing internal gypsum boards, or modifying the external facades. The unitized system replaces the need for having individual systems for exterior and internal applications.
[0033]
[0030] Further, the insulation material provides lower thermal transmittance compared to conventional masonry and glazing products. Also, the composite panel and the composite wall system offer easy maintenance of the exterior panelling.
[0034]
[0031] It is to be understood that the aspects and embodiments of the present disclosure described above may be used in combination with each other. Several of the aspects and embodiments may be combined together to form a further embodiment of the present disclosure.
[0035]
[0032] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
[0036] BRIEF DESCRIPTION OF FIGURES
[0037]
[0033] The novel features and characteristics of the disclosure are set forth in the description. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following description of an illustrative embodiment when read in conjunction with the accompanying drawings. One or more embodiments are now described, by way of example only, with reference to the accompanying drawings wherein like reference numerals represent like elements and in which:
[0038]
[0034] FIG. 1 illustrates an exemplary composite wall system, in accordance with an embodiment of the present disclosure;
[0039]
[0035] FIG. 2 illustrates a perspective view of a first spandrel of the composite wall system of FIG. 1, in accordance with an embodiment of the present disclosure;
[0040]
[0036] FIG. 3 illustrates a perspective view of a second spandrel of the composite wall system of FIG. 1, in accordance with an embodiment of the present disclosure;
[0037] FIG. 4 illustrates a perspective view of a composite panel of the composite wall system of FIG. 1, in accordance with an embodiment of the present disclosure;
[0041]
[0038] FIG. 5 A illustrates a side view of the composite panel of FIG. 4, in accordance with an embodiment of the present disclosure;
[0042]
[0039] FIG. 5B illustrates a cross sectional view of the composite panel of FIG. 4, in accordance with an embodiment of the present disclosure;
[0043]
[0040] FIG. 6 illustrates a top perspective view of a lower frame member of the composite panel of FIG. 4, in accordance with an embodiment of the present disclosure;
[0044]
[0041] FIG. 7 illustrates a side view of the lower frame member of FIG. 6, the lower frame member comprising at least one panel mating provision, in accordance with a first embodiment of the present disclosure;
[0045]
[0042] FIG. 8 illustrates a side view of the lower frame member of FIG. 6, the lower frame member comprising at least one panel mating provision, in accordance with an embodiment of the present disclosure;
[0046]
[0043] FIG. 9 illustrates a bottom perspective view of an upper frame member of the composite panel of FIG. 4, in accordance with an embodiment of the present disclosure; and
[0047]
[0044] FIG. 10 illustrates a flow chart depicting a method of installation of the composite panel of FIG. 4, in accordance with an embodiment of the present disclosure.
[0048]
[0045] Skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the drawings may be exaggerated relative to other elements to help to improve understanding of embodiments of the present disclosure.
[0049] DETAILED DESCRIPTION
[0050]
[0046] While the present disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the FIGS, and will be described in detail below. It should be understood, however that it is not intended to limit the present disclosure to the particular forms disclosed, but on the contrary, the present disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
[0047] Before describing detailed embodiments, it may be observed that the novelty and inventive step that are in accordance with the present disclosure resides in a composite panel, a composite wall system, and a method of installation of the composite panel. It is to be noted that a person skilled in the art can be motivated from the present disclosure and modify the various constructions of the composite panel, the composite wall system, and the method. However, such modification should be construed within the scope of the present disclosure. Accordingly, the drawings are showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.
[0051]
[0048] In the present disclosure, the term “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment or implementation of the present subject matter described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.
[0052]
[0049] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a device that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such setup or device. In other words, one or more elements in a system or apparatus proceeded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
[0053]
[0050] The terms like “at least one” and “one or more” may be used interchangeably or in combination throughout the description.
[0054]
[0051] Pursuant to an aspect, in an embodiment, a composite panel is disclosed. The composite panel comprises a frame structure. The frame structure comprises an upper frame member having at least two upper compartments formed at an internal side thereof. The frame structure further comprises a lower frame member having at least two lower compartments formed at an internal side thereof, and at least one panel mating provision at an external side thereof. The frame structure furthermore comprises a first side frame member, and a second side frame member. Each of the first side frame member and the second side frame member comprise coupling provisions that facilitate coupling the composite panel to an adjacent composite panel. The composite panel further comprises a decorative member secured between a frontmost upper compartment of the at least two upper compartments and a frontmost lowercompartment of the at least two lower compartments. The composite panel furthermore comprises at least one board coupled to a rearmost upper compartment of the at least two upper compartments and a rearmost lower compartment of the at least two lower compartments. Further, the composite panel optionally comprises an insulation material provided between the decorative member and the at least one board.
[0055]
[0052] In an embodiment, the at least one panel mating provision of the lower frame member comprises connector pins. Each connector pin is adapted to press-fit into a corresponding hole defined in an external body for coupling the composite panel to the external body. In another embodiment, the at least one panel mating provision of the lower frame member comprises a guide rail. The guide rail is configured to engage with a complimentary-shaped guide rail defined in an external body for coupling the composite panel to the external body. The guide rail is further configured to facilitate a sliding movement of the composite panel on the external body. Further, the at least one panel mating provision of the lower frame member facilitates locking the composite panel with the external body, upon an angular movement of the composite panel from an inclined position to an upright position.
[0056]
[0053] In an embodiment, the coupling provisions of the first side frame member comprises one or more snap-fit male connectors along a length of the first side frame member. The one or more snap-fit male connectors of the first side frame member is configured to facilitate coupling with a corresponding snap-fit female connector on a second side frame member of the adjacent composite panel. In another embodiment, the coupling provisions of the second side frame member comprises one or more snap-fit female connectors along a length of the second side frame member. The one or more snap-fit female connectors of the second side frame member is configured to facilitate coupling with a corresponding snap-fit male connector on a first side frame member of the adjacent composite panel. Further, the upper frame member, at an external side thereof, defines fastening holes that facilitate fastening the composite panel to an external body.
[0057]
[0054] In an embodiment, the at least one board comprises a first board, and a second board coupled to the first board and can be made of plasterboard, cement board, magnesium oxide board, cardboard, wood-based boards, fiber reinforced composites, or wood fiber boards. The at least one board is one of pre-finished board and sandwich panels. Further, the decorative member is secured with the upper frame member and the lower frame member by a sealant. The decorative member is made of glass,photovoltaic panels, aluminum-based composite panels, exterior grade wall linings, gypsum-based boards, cement-based boards, textile reinforced concrete panels, and exterior grade laminated panels. Furthermore, the insulation material comprises mineral wool, glass wool, fiberglass, blown-in insulation, expanded polystyrene (EPS), extruded polystyrene (XPS), or polyurethane foam. Also, the frame structure is made of aluminum, GI steel or uPVC.
[0058]
[0055] Pursuant to another aspect, in an embodiment, a composite wall system is disclosed. The composite wall system comprises a first spandrel adapted to be coupled to a floor of a building, and a second spandrel adapted to be coupled to a ceiling of the building. The composite wall system further comprises the composite panel as discussed above. The composite panel is adapted to couple with the first spandrel and the second spandrel. The first spandrel comprises at least one spandrel mating provision that is adapted to engage with the at least one panel mating provision of the composite panel for coupling the composite panel to the first spandrel. The second spandrel defines a plurality of fastening holes that facilitate fastening the composite panel to the second spandrel.
[0059]
[0056] In an embodiment, the at least one spandrel mating provision of the first spandrel comprises spandrel holes. Each spandrel hole is adapted to receive a corresponding connector pin of the lower frame member of the composite panel for press-fitting the composite panel into the first spandrel. In another embodiment, the at least one spandrel mating provision of the first spandrel comprises a spandrel guide rail that is configured to receive and engage with the guide rail of the lower frame member of the composite panel for coupling the composite panel to the first spandrel. The at least one panel mating provision of the lower frame member facilitates locking the composite panel with the at least one spandrel mating provision of the first spandrel, upon an angular movement of the composite panel from an inclined position to an upright position.
[0060]
[0057] The first spandrel and the second spandrel comprise fastening holes adapted to receive fasteners for coupling the first spandrel and the second spandrel to the floor and the ceiling, respectively.
[0061]
[0058] Pursuant to yet another aspect, in an embodiment, a method of installation of the composite panel is disclosed. The method comprises positioning the at least one panel mating provision of the lower frame member of the composite panel with at least one spandrel mating provision of a first spandrel. The method further comprisesangularly moving the lower frame member from an inclined position to an upright position such that the at least one panel mating provision of the lower frame member locks with the at least one spandrel mating provision of the first spandrel. The method furthermore comprises coupling the upper frame member of the composite panel to a second spandrel.
[0062]
[0059] Reference will now be made to the exemplary embodiments of the present disclosure, as illustrated in the accompanying drawings. Wherever possible, same numerals will be used to refer to the same or like parts. Embodiments of the disclosure are described in the following paragraphs with reference to FIGS. 1 to 10. In FIGS. 1 to 10, the same element or elements which have same functions are indicated by the same reference signs.
[0063]
[0060] Referring to FIG. 1, a composite wall system (10) is illustrated. Without limiting the scope of protection of the present disclosure, the composite wall system (10) may be utilized in a variety of applications, including industrial buildings (such as warehouses, factories, and distribution centers), commercial buildings (such as retail spaces and office complexes) and residential projects (for example, prefabricated homes, etc.). Additionally, the composite wall system (10) may be utilized for exterior wall applications, prefabricated construction, modular and unitized construction, external facades, etc. In accordance with the present disclosure, the composite wall system (100) may be employed for infill systems comprising at least two slabs. In said embodiment, the composite wall system (100) may be fitted between the slabs of the infill system. As shown in FIG. 1, the composite wall system (10) comprises a composite panel (100), a first spandrel (20) and a second spandrel (50). The first spandrel (20) and the second spandrel (50) may be understood as the elements adapted to connect the composite panel (100), for example the end portions of the composite panel (100), to floor and ceiling of a building. For example, for an infill system having a top slab and a bottom slab, the first spandrel (20) and the second spandrel (50) may be understood as the elements adapted to connect the composite panel (100) to the top and bottom slabs of the infill system.
[0064]
[0061] Referring to FIGS. 1 and 2, the first spandrel (20) is adapted to be coupled to a floor (12) of a building (not shown). Further, referring to FIGS. 1 and 3, the second spandrel (50) is adapted to be coupled to a ceiling (14) of the building. In accordance with the present disclosure, the composite panel (100) is adapted to couple with the first spandrel (20) and the second spandrel (50) such that the composite panel (100) extendsbetween the floor (12) and the ceiling (14) of the building, for example, between a floor and a ceiling of a level of a multi-level building. In an embodiment, the composite panel (100) may be coupled with the first spandrel (20) and the second spandrel (50) by a sealant that may comprise, but not limited to, silicone sealant or PU (polyurethane) based sealant.
[0065]
[0062] Referring to FIG. 2, in an embodiment, the first spandrel (20) may be embodied as a first wall (22) and a second wall (24) extending transversely from the first wall (22). As shown in FIG. 2, the second wall (24) of the first spandrel (20) comprises fastening holes (26) that are adapted to receive fasteners (not shown) for coupling the first spandrel (20) to the floor (12), as shown in FIG. 1. Still referring to FIG. 2, the first spandrel (20) may comprise at least one spandrel mating provision (30). In an embodiment, the at least one spandrel mating provision (30) may be formed on the second wall (24) of the first spandrel (20). The at least one spandrel mating provision (30) may be adapted to engage with the at least one panel mating provision (152), as shown in FIGS. 7 and 8, of the composite panel (100) for coupling the composite panel (100) to the first spandrel (20). In an embodiment, the at least one spandrel mating provision (30) of the first spandrel (20) may comprise spandrel holes (32). In another embodiment, the at least one spandrel mating provision (30) of the first spandrel (20) comprises a spandrel guide rail (not shown).
[0066]
[0063] Further, referring to FIG. 3, in an embodiment, the second spandrel (50) may be embodied as a first wall (52) and at least one second wall (54) extending transversely from the first wall (52). In some embodiments, the second spandrel (50) may have two second walls (54) extending transversely from the first wall (52). The second wall (54) of the second spandrel (50) may comprise fastening holes (56) that are adapted to receive fasteners (not shown) for coupling the second spandrel (50) to the ceiling (14). In an embodiment where the composite panel (100) is utilized in a ground floor of a building, the first spandrel (20) is fastened to the floor and the second spandrel (50) is fastened to the ceiling as shown in FIG. 1. In other embodiments where the composite panel (100) is utilized in a first floor of a building or in other floors thereafter, the second spandrel (50) can act as both the first spandrel fastened to the floor as well as the second spandrel fastened to the ceiling.
[0067]
[0064] In an alternate embodiment where the composite panel (100) is utilized for a ground floor of a building, the second spandrel (50) may comprise two second walls (54) extending transversely from the first wall (52). Each second wall (54) of the secondspandrel (50) may comprise fastening holes (56) that are adapted to receive fasteners (not shown) for coupling the second spandrel (50) to the ceiling (14). In other embodiments, referring to FIG. 3, where the composite panel (100) is utilized for a multi-level building, the second spandrel (50) may comprise two second walls (54) extending transversely from the first wall (52). In said embodiment, both second walls (54a, 54b) amongst the two second walls (54) may comprise the fastening holes (56) that are adapted to receive fasteners (not shown) for coupling the second spandrel (50) to the ceiling (14) or floor (12). Additionally, a top second wall (54b) amongst the two second walls (54) may comprise at least one spandrel mating provision (60), similar to the spandrel mating provision (30) of the first spandrel (20). In an embodiment, the at least one spandrel mating provision (60) is adapted to engage with the at least one panel mating provision (152), as shown in FIGS. 7 and 8, of the composite panel (100) for coupling the composite panel (100) to the second spandrel (50) while providing the composite panel (100) on levels (of the multi-level building) above the ground level. In an embodiment, the at least one spandrel mating provision (60) may comprise spandrel holes (62). In another embodiment, the at least one spandrel mating provision (60) comprises a spandrel guide rail (not shown).
[0068]
[0065] Further, still referring to FIG. 1, the second spandrel (50) may define a plurality of fastening holes (not visible in FIGS. 1 and 3). In an embodiment, the plurality of fastening holes may be defined in the first wall (52) of the second spandrel (50). The plurality of fastening holes of the second spandrel (50) facilitates fastening the composite panel (100) to the second spandrel (50). Referring to FIG. 4, the plurality of fastening holes defined in the first wall (52) of the second spandrel (50) may align with fastening holes (132) of the composite panel (100) to receive fasteners (not shown) for coupling the composite panel (100) with the second spandrel (50) during installation of the composite panel (100). In accordance with the present disclosure, the fastening holes (56) in the second wall (54) of the second spandrel (50) facilitate providing a vertical coupling of the second spandrel (50) to the ceiling (14). Further, the fastening holes defined in the first wall (52) of the second spandrel (50), in conjunction with the fastening holes (132) of the composite panel (100), facilitate providing a horizontal coupling of the composite panel (100) to the second spandrel (50) during installation of the composite panel (100). Said horizontal coupling prevents the composite panel (100) from falling backwards inside the building.
[0066] FIGS. 4, 5A and 5B illustrate the composite panel (100) of the composite wall system (10). The composite panel (100) comprises a frame structure (110), a decorative member (170), at least one board (180), and optionally an insulation material (190). In accordance with the present disclosure, the insulation material (190) may be sandwiched between the decorative member (170), and the at least one board (180) to form a sandwich composite panel (100), which is fitted within the frame structure (110) to form the composite panel (100) of the present disclosure. Alternatively, the board (180) referenced in a few embodiments could be pre-sandwiched with an insulation material. Referring to FIG. 4, the frame structure (110) comprises an upper frame member (120), a lower frame member (140), a first side frame member (160), and a second side frame member (164) coupled with each other to form a rectangular frame. Coupling of the upper frame member (120), a lower frame member (140), a first side frame member (160), and a second side frame member (164) can be envisaged by one or more means of bolting, screwing, fastening, using adhesives, any welding techniques and other equivalent conventional coupling means.
[0069]
[0067] In an assembled configuration of the composite panel, the decorative member (170), the at least one board (180), and optionally the insulation material (190) is fitted within the said rectangular frame or the frame structure (110).
[0070]
[0068] Referring to FIGS. 4, 5A, 5B and 9, the upper frame member (120) may be embodied to have a cuboidal structure having an internal side (120a) and an external side (120b). The internal side (120a) may be understood as a side of the upper frame member (120) towards the lower frame member (140) and the external side (120b) may be understood as a side of the upper frame member (120) away from the lower frame member (140), in an assembled configuration of the composite panel (100). The upper frame member (120) defines at least two upper compartments (122) formed at the internal side thereof (120a). The at least two upper compartments (122) may be separated from each other by walls (124). In the exemplary embodiment of FIG. 9, the upper frame member (120) defines at least three upper compartments (122) formed at the internal side thereof (120a). As shown in FIG. 9, the at least three upper compartments (122) may be separated from each other by the walls (124). At the external side (120b) thereof, the upper frame member (120) may comprise an upper coupling member (130), as shown in FIGS. 4 and 9. The upper coupling member (130) may define fastening holes (132), as shown in FIG. 4, that facilitate fastening the composite panel (100) to an external body. Referring to FIG. 1, in an embodiment, thefastening holes (132) of the upper frame member (120) facilitate fastening the composite panel (100) to the second spandrel (50) of the composite wall system (10), 1.e., the horizontal coupling of the composite panel (100) to the second spandrel (50). In an exemplary embodiment, the fastening holes (132) of the upper frame member (120) may align with the plurality of fastening holes defined in the first wall (52) of the second spandrel (50) to receive fasteners for fastening the composite panel (100) to the second spandrel (50).
[0071]
[0069] Referring to FIGS. 4, 5A, 5B and 6, the lower frame member (140) may be embodied to have a cuboidal structure having an internal side (140a) and an external side (140b). The internal side (140a) may be understood as a side of the lower frame member (140) towards the upper frame member (120) and the external side (140b) may be understood as a side of the lower frame member (140) away from the upper frame member (120), in an assembled configuration of the composite panel (100). The lower frame member (140) defines at least two lower compartments (142) formed at the internal side (140a) thereof. The at least two lower compartments (142) may be separated from each other by walls (144). In the exemplary embodiment of FIG. 6, the lower frame member (140) defines at least three lower compartments (142) formed at the internal side (140a) thereof. As shown in FIG. 6, the at least three lower compartments (142) may be separated from each other by the walls (144). At the external side (140b) thereof, the lower frame member (140) may comprise a lower coupling member (150), as shown in FIGS. 5 and 6. The lower coupling member (150) may further comprise at least one panel mating provision (152), as shown in FIGS. 7 and 8, that facilitate fastening the composite panel (100) to an external body. Referring to FIGS. 1, 6, 7 and 8, in an embodiment, the at least one panel mating provision (152) of the lower frame member (140) facilitates fastening the composite panel (100) to the first spandrel (20) of the composite wall system (10).
[0072]
[0070] Referring to FIG. 7, in an embodiment, the at least one panel mating provision (152) of the lower frame member (140) may comprise connector pins (154), one of which is visible in FIG. 7. In accordance with the present disclosure, during assembly of the composite wall system (10), each connector pin (154) of the lower frame member (140) may press-fit into a corresponding hole defined in an external body for coupling the composite panel (100) to the external body. For instance, referring to FIGS. 1 and 2, during assembly of the composite wall system (10) in which the composite panel (100) is fastened to the first spandrel (20), each connector pin (154) of the lower framemember (140) may press-fit into the corresponding spandrel hole (32), i.e., the spandrel mating provision (30), defined in the second wall (24) of the first spandrel (20) for coupling the composite panel (100) to the first spandrel (20).
[0073]
[0071] In another embodiment, referring to FIG. 8, the at least one panel mating provision (152) of the lower frame member (140) may comprise a guide rail (156), as shown in FIG. 8. The guide rail (156) of the lower frame member (140) may be configured to engage with a complimentary-shaped guide rail (not shown) defined in an external body for coupling the composite panel (100) to the external body. For instance, during assembly of the composite wall system (10) in which the composite panel (100) is fastened to the first spandrel (20), the guide rail (156) of the lower frame member (140) may engage with the complimentary-shaped guide rail (not shown), i.e., the spandrel guide rail, defined in the second wall (24) of the first spandrel (20) for coupling the composite panel (100) to the first spandrel (20). Further, within the scope of the present disclosure, the guide rail (156) of the lower frame member (140) may be configured to facilitate a sliding movement of the composite panel (100) on the external body, for example, the first spandrel (20). For example, the guide rail (156) of the lower frame member (140) may slide over the complimentary-shaped guide rail of the external body, for example, the spandrel guide rail of the first spandrel (20).
[0074]
[0072] In accordance with the present disclosure, the at least one panel mating provision (152) of the lower frame member (140) may facilitate locking the composite panel (100) with the external body, for example with the spandrel mating provision (30), upon an angular movement of the composite panel (100) from an inclined position to an upright position. For instance, during assembly of the composite wall system (10) in which the composite panel (100) is fastened to the first spandrel (20), each connector pin (154) of the lower frame member (140) may rest upon the corresponding spandrel hole (32) defined in the second wall (24) of the first spandrel (20) in the inclined position of the composite panel (100) with respect to the first spandrel (20). Further, upon angular movement of the composite panel (100) from the inclined position to the upright position, the connector pins (154) of the lower frame member (140) may press-fit into the corresponding spandrel hole (32) defined in the second wall (24) of the first spandrel (20) for coupling the composite panel (100) to the first spandrel (20).
[0075]
[0073] Referring to FIG. 4, the frame structure (110) comprises the first side frame member (160), and the second side frame member (164). The first side frame member (160) and the second side frame member (164) extend between the upper frame member(120) and the lower frame member (140) on opposite sides of the composite panel (100). In accordance with the present disclosure, each of the first side frame member (160) and the second side frame member (164) comprises coupling provisions that facilitate coupling the composite panel (100) to an adjacent composite panel (not shown). In an exemplary embodiment, the coupling provisions of the first side frame member (160) and the second side frame member (164) of the composite panel (100) comprise snap-fit connectors for coupling the composite panel (100) to the adjacent composite panel.
[0076]
[0074] In an embodiment, the coupling provisions of the first side frame member (160) comprises one or more snap-fit male connector (162) along a length of the first side frame member (160). The one or more snap-fit male connectors (162) of the first side frame member (160) are configured to facilitate coupling with a corresponding snap-fit female connector (166) on a second side frame member (164) of the adjacent composite panel. In a further embodiment, the coupling provisions of the second side frame member (164) comprises one or more snap-fit female connectors (166) along a length of the second side frame member (164). The one or more snap-fit female connectors (166) of the second side frame member (164) configured to facilitate coupling with a corresponding snap-fit male connector (162) on a first side frame member (160) of the adjacent composite panel.
[0077]
[0075] Without limiting the scope of protection of the present disclosure, the frame structure (110) may be made of aluminum, GI steel or uPVC (unplasticized Polyvinyl Chloride). In particular, the upper frame member (120), the lower frame member (140), the first side frame member (160) and the second side frame member (164) may be made of aluminum, GI steel or uPVC (unplasticized Polyvinyl Chloride). In a further embodiment, the frame structure (110) may comprise vibration absorbing material provided in the upper frame member (120), the lower frame member (140), the first side frame member (160) and the second side frame member (164) for dampening vibrations induced or introduced in the composite panel (100) or the composite wall system (10). The vibration absorbing material may comprise, but not limited to, rubber, EPDM (ethylene propylene diene monomer), butyl, neoprene or specific adhesive tapes.
[0078]
[0076] Referring to FIGS. 4 and 5, the composite panel (100) comprises the decorative member (170) secured at one side of the upper frame member (120) and a corresponding side of the lower frame member (140). In an embodiment, the decorative member (170)may be secured between a frontmost upper compartment of the at least two upper compartments (122) and a frontmost lower compartment of the at least two lower compartments (142), for example, when one installed composite panel (100) is seen from outside the building. In an exemplary embodiment in which the upper frame member (120) and the lower frame member (140) comprise three upper compartments (122) and three lower compartments (142), respectively, the decorative member (170) may be secured between a first upper compartment and a first lower compartment, for example the first upper compartment and the first lower compartment from a front side of the composite panel (100), i.e., when seen from the outside of the building. Referring to exemplary embodiments of FIGS. 6 and 9, in which the upper frame member (120) and the lower frame member (140) comprise three upper compartments (122) and three lower compartments (142), respectively, the decorative member (170) may be secured between a first upper compartment (122a) and a first lower compartment (142a), for example the first upper compartment (122a) and the first lower compartment (142a) from a front side of the composite panel (100), i.e., when seen from the outside of the building. The decorative member (170) may be secured with the upper frame member (120) and the lower frame member (140) by a sealant. The sealant may comprise, but not limited to, silicone sealant or PU (polyurethane) based sealant. In other embodiments, the decorative member (170) may be press-fittingly secured or fastened (using fasteners) with the upper frame member (120) and the lower frame member (140). The sealant delays potential breakage and securely bonds the decorative member with the upper frame member and the lower frame member. In one other non-limiting embodiment of the present disclosure, optionally a weathering sealant can be applied evenly over and above the said sealant to prevent condensation and protect the said sealant from moisture and dirt. In yet another non-limiting embodiment of the present disclosure, additionally a structural sealant can be used to bond the decorative member with the upper frame member and the lower frame member and enhance structural stability to the composite wall panel. Together, the primary sealant, weathering sealant and the structural sealant enhances the overall stability and prevents the decorative member from cracking. In certain other embodiments, a spacer bar (not shown in figures) is used as a frame that separates the glass panes, creating an insulating cavity. Furthermore, a desiccant may be used within the spacer bar to absorb any moisture trapped in the insulating cavity.
[0077] In accordance with the present disclosure, the decorative member (170) may comprise, but not limited to, glass, photovoltaic panels, aluminum-based composite panels, exterior grade wall linings, gypsum-based boards, cement-based boards, textile reinforced concrete panels, and exterior grade laminated panels, or the like.
[0079]
[0078] Further, still referring to FIGS. 4 and 5, the composite panel (100) may comprise at least one board (180) coupled to the upper frame member (120) and the lower frame member (140) at a side opposite to the decorative member (170). In an embodiment, the at least one board (180) may be coupled to a rearmost upper compartment of the at least two upper compartments (122) and a rearmost lower compartment of the at least two lower compartments (142), for example, when one installed composite panel (100) is seen from outside the building. In an exemplary embodiment in which the upper frame member (120) and the lower frame member (140) comprise two upper compartments (122) and two lower compartments (142), respectively, the at least one board (180) may be secured between a second upper compartment and a second lower compartment, for example the second upper compartment and the second lower compartment from the front side of the composite panel (100), i.e., when seen from the outside of the building. Referring to exemplary embodiments of FIGS. 6 and 9, in which the upper frame member (120) and the lower frame member (140) comprise three upper compartments (122) and three lower compartments (142), respectively, the at least one board (180) may be secured between a third upper compartment (122c) and a third lower compartment (142c), for example the third upper compartment (122c) and the third lower compartment (142c) from the front side of the composite panel (100), i.e., when seen from the outside of the building.
[0080]
[0079] The at least one board (180) may be secured with the upper frame member (120) and the lower frame member (140) by a sealant. The sealant may comprise, but not limited to, silicone sealant or PU (polyurethane) based sealant. In other embodiments, the at least one board (180) may be press-fittingly secured or fastened (using fasteners) with the upper frame member (120) and the lower frame member (140).
[0081]
[0080] In an embodiment, the at least one board (180) may comprise a combination of boards coupled to each other by construction elements, such as studs (not visible). In an embodiment, the at least one board may comprise a first board and a second board sandwiched with the first board. In an exemplary embodiment of the present disclosure, the at least one board (180) may comprise a first board (182), and a second board (184)coupled to the first board (182) by a plurality of studs (not visible). The studs may be made of metal, for example aluminum.
[0082]
[0081] In accordance with the present disclosure, the at least one board (180) may comprise a pre-finished board or a sandwich panel. A sandwich panel may be understood as two or more individual panels coupled to each other to create a single assembly with or without metal. Exemplary board (180) may comprise, but not limited to, plasterboard, cement board, magnesium oxide board, cardboard, wood-based boards, fiber reinforced composites, or wood fiber boards.
[0083]
[0082] In an additional embodiment, an electrical routing hose (not shown in figures) can be provided to guide electrical wiring through the composite panel. An electrical base board may serve as the foundation for the electrical system, providing necessary support and structure for safely routing electrical circuits throughout the composite panel. An electrical switch board can be mounted on the base board for controlling power distribution. Together, the electrical base board and switch board ensure efficient and organized power management throughout the composite panel.
[0084]
[0083] Within the scope of protection of the present disclosure, a person skilled in the art can readily comprehend that, in some embodiment, the at least one board (180) of the composite panel (100) may be replaced with the decorative member (170) such that the composite panel (100) comprises a first decorative member (170) coupled to the rearmost upper compartment of the at least two upper compartments (122) and the rearmost lower compartment of the at least two lower compartments (142), and a second decorative member (170) coupled to the frontmost upper compartment of the at least two upper compartments (122) and the frontmost lower compartment of the at least two lower compartments (142), for example, when one installed composite panel (100) is seen from outside the building.
[0085]
[0084] In an alternate application, said composite panel can be envisaged to be used as a window or in a retrofitting solution to replace an existing composite panel by making suitable changes to the upper frame member, lower frame member and the side frame members. In an exemplary embodiment, the disclosed upper and lower frame members and the side frame members can be designed as a stepped profile having a 4 inch step to accommodate the composite wall panel components and be compatible with the securing structure of the window or the replacement panel.
[0086]
[0085] Furthermore, still referring to FIGS. 4 and 5, the composite panel (100) may further comprise an insulation material (190) provided between the decorative member(170) and the at least one board (180). For instance, in the exemplary embodiment of FIGS. 6 and 9, in which the upper frame member (120) and the lower frame member (140) comprise three upper compartments (122) and three lower compartments (142), respectively, the insulation material (190) may be provided in the second upper compartment (122b) and the second lower compartment (142b). In accordance with the present disclosure, the insulation material (190) may comprise, but not limited to, mineral wool, glass wool, fiberglass, blown-in insulation, expanded polystyrene (EPS), extruded polystyrene (XPS), or polyurethane foam.
[0087]
[0086] Referring to FIG. 10, a method (1000) of installation of the composite panel (100) is depicted. At step (1010), the method (1000) comprises positioning the at least one panel mating provision (152) of the lower frame member (140) of the composite panel (100) with at least one spandrel mating provision (30) of the first spandrel (20). In an embodiment, positioning the at least one panel mating provision (152) with at least one spandrel mating provision (30) comprises positioning connector pins (154) of the lower frame member (140) with the corresponding spandrel hole (32) defined in the first spandrel (20). In another embodiment, positioning the at least one panel mating provision (152) with at least one spandrel mating provision (30) comprises positioning the guide rail (156) with the complimentary-shaped spandrel guide rail defined in the second wall (24) of the first spandrel (20).
[0088]
[0087] Further, at step (1020), the method (1000) comprises angularly moving the lower frame member (140) from the inclined position to the upright position such that the at least one panel mating provision (152) of the lower frame member (140) locks with the at least one spandrel mating provision (30) of the first spandrel (20). In an embodiment, angularly moving the lower frame member (140) comprises press-fitting the connector pins (154) of the lower frame member (140) into the corresponding spandrel hole (32) defined in the second wall (24) of the first spandrel (20), upon angular movement of the lower frame member (140) from the inclined position to the upright position, for coupling the composite panel (100) to the first spandrel (20). In another embodiment, angularly moving the lower frame member (140) comprises engaging the guide rail (156) of the lower frame member (140) with the complimentary-shaped spandrel guide rail defined in the second wall (24) of the first spandrel (20), upon angular movement of the lower frame member (140) from the inclined position to the upright position, for coupling the composite panel (100) to the first spandrel (20).
[0088] At step (1030), the method (1000) comprises coupling the upper frame member (120) of the composite panel (100) to the second spandrel (50) of the composite wall system (10). In an embodiment, coupling the upper frame member (120) to the second spandrel (50) comprises fastening, by fasteners, the composite panel (100) to the second spandrel (50).
[0089]
[0089] In one exemplary working implementation of the present disclosure, the composite panel (100) may comprise two gypsum boards (182, 184) on the interior side and a glass (170) (i.e., the decorative member (170)) on the exterior side, separated by a layer of insulation material (190) for example, when one installed composite panel (100) is seen from outside the building. The gypsum boards (182, 184) on the internal side of the composite panel (100) allow the users to have the necessary privacy and get a feel of a residential space. The gypsum boards (182, 184) further act as a discontinuity between the metal frame structure (110) and the internal residential space to prevent heat conductance (thermal bridging) into the internal space. In an embodiment, the two gypsum boards (182, 184) are supported by the plurality of metal studs, for example three metal studs, with the gypsum boards (182, 184) being fixed to the metal studs by screw fasteners. In accordance with the present disclosure, the metal studs are connected to the frame structure (110) and provide additional stability to the composite panel (100).
[0090]
[0090] Additionally, the insulation material (190) provided between the glass (170) and the gypsum boards (182, 184) of the composite panel (100) facilitate enhanced acoustic and thermal performance. In accordance with the present disclosure, the frame structure (110) is used to combine the gypsum boards (182, 184), the insulation material (190), and the glass (170) in place and in the form of a unified composite panel (100).
[0091]
[0091] In an implementation, the lower frame member (140) of the composite panel (100) comprises panel mating provisions (152), for example connector pins (154), or the guide rail (156), that allow alignment and easy installation of the prefabricated composite panel (100) onto the first spandrel (20) (connected to the floor (12)) by enabling a tilt to lock in place between the lower frame member (140) and the first spandrel (20). In further implementations, a rubber or rubber-like material may be placed between the upper and lower frame members (120, 140) and the glass (170) at the top and bottom to absorb vibrations and prevent cracking.
[0092]
[0092] For installation of the composite panel (100), the method comprises securing the first spandrel (20) to the floor (12) of the building, for example by fasteners.Subsequently, the method comprises securing the second spandrel (50) to the ceiling (14) of the building, for example by fasteners. Thereafter, the composite panel (100) is positioned at an angle, initially inserted into the first spandrel (20), and then moved from the inclined position to the upright position to lock the composite panel (100) with the first spandrel (20). Once in place, the composite panel (100) is fastened to the second spandrel (50) using fasteners. In accordance with the present disclosure, the first spandrel (20) and the second spandrel (50) provide a barrier for external environment to interact with the internal residential space as well as the internal prefabricated composite unit. Also, the first and second spandrels (20, 50) provide a rigid structure to support the composite panel (100), by providing a robust connection between the floor (12) and the ceiling (14) of the building and the composite panel (100).
[0093]
[0093] The configuration of the composite panel (100) allows easy and efficient fixing of the prefabricated composite wall (10) from the interior of the building. Additionally, the first side frame member (160) and the second side frame member (164) provided on the either side of the composite panel (100) have complementary male and female connectors (162, 166) that facilitate attachment to adjacent composite panels by acting as installation guides, allowing the end user to align and install the adjacent composite panel easily and quickly, and thereby reduce the time needed for overall installation. To complete the interior, any visible frame structure at the top and bottom may be concealed with gypsum boards, resulting in a traditional construction aesthetic inside, while presenting a modern facade outside. Additionally, owing to the modular configuration of the composite panel (100), any repairs, replacements and / or changes may be made on either side of the composite panel (100) without dismantling the entire composite panel (100) or the composite wall system (10).
[0094]
[0094] Within the scope of the present disclosure, the composite panel (100) and the composite wall system (10) of the present disclosure provide a modular system for connecting the spandrel (20, 50) or the external body and the composite panel (100). Further, the panel mating provisions (152) of the lower frame member (140) of the composite panel (100) (i.e., tilt and lock functionality of the lower frame member (140)) allow easy and quick installation of the modular system. Moreover, unitised composite panel comprising glass (170), insulation (190) and gypsum boards (180) into a single modular unit reduces inventory demand during installation. Also, the composite panel (100) facilitates installation of the unitized composite panel from the inside of the building without the use of external help like cranes, lifting equipment, scaffolding, etc.Additionally, owing to the structural configuration of the composite panel (100), no assembly of components is required, thus leading to zero assembly time of the composite panel (100) onsite, for installation.
[0095]
[0095] In accordance with the present disclosure, the composite panel (100) and the composite wall system (10) provide non-load bearing units / system, thereby leading to less material usage. Further, the gypsum boards (182, 184) in the composite panel (100) improve the perception for the residential users, by providing visual privacy (opaqueness) and ambience of a residential area. Also, the modular composite wall (10) system provides freedom to the residential user for setting up the residential areas as well as the external system as per choice, for example, changing internal gypsum boards, or modifying the external facades. The unitized system replaces the need for having individual systems for exterior and internal applications.
[0096]
[0096] Further, the insulation material (190) provides lower thermal transmittance compared to conventional masonry and glazing products. Also, the composite panel (100) and the composite wall system (10) offer easy maintenance of the exterior panelling.
[0097]
[0097] The various embodiments of the present disclosure have been described above with reference to the accompanying drawings. The present disclosure is not limited to the illustrated embodiments; rather, these embodiments are intended to fully and completely disclose the subject matter of the disclosure to those skilled in this art. In the drawings, like numbers refer to like elements throughout. Thicknesses and dimensions of some components may be exaggerated for clarity.
[0098]
[0098] Herein, the terms “attached”, “connected”, “interconnected”, “contacting”, “mounted”, “coupled” and the like can mean either direct or indirect attachment or contact between elements, unless stated otherwise.
[0099]
[0099] Well-known functions or constructions may not be described in detail for brevity and / or clarity. As used herein the expression “and / or” includes any and all combinations of one or more of the associated listed items.
[0100]
[0100] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising”, “includes” and / or “including” when used in this specification, specify the presence of stated features, operations, elements, and / orcomponents, but do not preclude the presence or addition of one or more other features, operations, elements, components, and / or groups thereof.
[0101]
[0101] While considerable emphasis has been placed herein on the particular features of this disclosure, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other modifications in the nature of the disclosure or the preferred embodiments will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.REFERENCE NUMERALS
[0102]
[0103]
[0104] EQUIVALENTS:
[0105]
[0102] The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0106]
[0103] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and / or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
[0107]
[0104] Any discussion of documents, acts, materials, devices, articles and the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
[0108]
[0105] The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher / lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
Claims
CLAIMS1. A composite panel (100), comprising:a frame structure (110), comprising:an upper frame member (120) having at least two upper compartments (122) formed at an internal side (120a) thereof;a lower frame member (140) havingat least two lower compartments (142) formed at an internal side (140a) thereof; andat least one panel mating provision (152) at an external side (140b) thereof;a first side frame member (160); anda second side frame member (164),each of the first side frame member (160) and the second side frame member (164) comprising coupling provisions that facilitate coupling the composite panel (100) to an adjacent composite panel; a decorative member (170) secured between a frontmost upper compartment (122a) of the at least two upper compartments (122) and a frontmost lower compartment (142a) of the at least two lower compartments (142); and at least one board (180) coupled to a rearmost upper compartment (122c) of the at least two upper compartments (122) and a rearmost lower compartment (142c) of the at least two lower compartments (142).
2. The composite panel (100) as claimed in claim 1, wherein the at least one panel mating provision (152) of the lower frame member (140) comprises connector pins (154),each connector pin (154) is adapted to press-fit into a corresponding hole (32) defined in an external body (20) for coupling the composite panel (100) to the external body (20).
3. The composite panel (100) as claimed in claim 1, wherein the at least one panel mating provision (152) of the lower frame member (140) comprises a guide rail (156),the guide rail (156) configured toengage with a complimentary-shaped guide rail defined in an external body (20) for coupling the composite panel (100) to the external body (20), andfacilitate a sliding movement of the composite panel (100) on the external body (20).
4. The composite panel (100) as claimed in claim 2 or 3, wherein the at least one panel mating provision (152) of the lower frame member (140) facilitates locking the composite panel (100) with the external body (20), upon an angular movement of the composite panel (100) from an inclined position to an upright position.
5. The composite panel (100) as claimed in claim 1, wherein the coupling provisions of the first side frame member (160) comprises one or more snap-fit male connectors (162) along a length of the first side frame member (160),the one or more snap-fit male connectors (162) of the first side frame member (160) configured to facilitate coupling with a corresponding snap-fit female connector (166) on a second side frame member (164) of the adjacent composite panel.
6. The composite panel (100) as claimed in claim 1, wherein the coupling provisions of the second side frame member (164) comprises one or more snap-fit female connectors (166) along a length of the second side frame member (164), the one or more snap-fit female connectors (166) of the second side frame member (164) configured to facilitate coupling with a corresponding snap-fit male connector (162) on a first side frame member (160) of the adjacent composite panel.
7. The composite panel (100) as claimed in claim 1, wherein the upper frame member (120), at an external side (120b) thereof, defines fastening holes that facilitate fastening the composite panel (100) to an external body (50).
8. The composite panel (100) as claimed in claim 1, wherein the at least one board (180) comprises:a first board (182); anda second board (184) coupled to the first board (182).
9. The composite panel (100) as claimed in claim 1, wherein the decorative member (170) is secured with the upper frame member (120) and the lower frame member (140) by a sealant.
10. The composite panel (100) as claimed in claim 1, wherein the at least one board (180) is made of plasterboard, cement board, magnesium oxide board, cardboard, wood-based boards, fiber reinforced composites, or wood fiber boards.
11. The composite panel (100) as claimed in claim 1, wherein the decorative member (170) is made of glass, photovoltaic panels, aluminum-based composite panels, exterior grade wall linings, gypsum-based boards, cement-based boards, textile reinforced concrete panels, and exterior grade laminated panels.
12. The composite panel (100) as claimed in claim 1, optionally comprises an insulation material (190) provided between the decorative member (170) and the at least one board (180)13. The composite panel (100) as claimed in claim 12, wherein the insulation material (190) comprises mineral wool, glass wool, fiberglass, blown-in insulation, expanded polystyrene (EPS), extruded polystyrene (XPS), or polyurethane foam.
14. The composite panel (100) as claimed in claim 1, wherein the frame structure (110) is made of aluminum, GI steel or UP VC.
15. A composite wall system (10), comprising:a first spandrel (20) adapted to be coupled to a floor (12) of a building; a second spandrel (50) adapted to be coupled to a ceiling (14) of the building; andthe composite panel (100) as claimed in any one of claims 1 to 14, the composite panel (100) adapted to couple with the first spandrel (20) and the second spandrel (50),wherein,the first spandrel (20) comprises at least one spandrel mating provision (30) that is adapted to engage with the at least one panel mating provision (152) of the composite panel (100) for coupling the composite panel (100) to the first spandrel (20), andthe second spandrel (50) defines a plurality of fastening holes that facilitate fastening the composite panel (100) to the second spandrel (50).
16. The composite wall system (10) as claimed in claim 15, wherein the at least one spandrel mating provision (30) of the first spandrel (20) comprises spandrel holes (32),each spandrel hole (32) is adapted to receive a corresponding connector pin (154) of the lower frame member (140) of the composite panel (100) for pressfitting the composite panel (100) into the first spandrel (20).
17. The composite wall system (10) as claimed in claim 15, wherein the at least one spandrel mating provision (30) of the first spandrel (20) comprises a spandrel guide rail that is configured to receive and engage with the guide rail (156) of the lower frame member (140) of the composite panel (100) for coupling the composite panel (100) to the first spandrel (20).
18. The composite wall system (10) as claimed in claim 16 or 17, wherein the at least one panel mating provision (152) of the lower frame member (140) facilitates locking the composite panel (100) with the at least one spandrel mating provision (30) of the first spandrel (20), upon an angular movement of the composite panel (100) from an inclined position to an upright position.
19. The composite wall system (10) as claimed in claim 15, wherein the first spandrel (20) and the second spandrel (50) comprise fastening holes (26, 56) adapted to receive fasteners for coupling the first spandrel (20) and the second spandrel (50) to the floor (12) and the ceiling (14), respectively.
20. A method (1000) of installation of the composite panel (100) as claimed in any of claims 1 to 14, the method (1000) comprising:positioning the at least one panel mating provision (152) of the lower frame member (140) of the composite panel (100) with at least one spandrel mating provision (30) of a first spandrel (20);angularly moving the lower frame member (140) from an inclined position to an upright position such that the at least one panel mating provision (152) of the lower frame member (140) locks with the at least one spandrel mating provision (30) of the first spandrel (20); andcoupling the upper frame member (120) of the composite panel (100) to a second spandrel (50).