Prefabricated wall panels and a method for manufacturing the same

Abstract

A multi-layer prefabricated wall panel for modular building and a method for manufacturing the same. The panel comprises a load-bearing and vapor barrier core layer; an interior insulating and utility installation layer bonded to the inner face of the core layer; an exterior sheet of a first rigid building material bonded to the interior insulating layer; and an interior sheet of a second building material bonded to the outer face of said core layer. The method for manufacturing the wall panel comprises the steps of forming a stack of the panel layers with adhesive coating between successive layers and bonding the layers to each other by uniform compressing forces.

1 . A multi-layer prefabricated wall panel, the panel having an interior and exterior planar surfaces and a thickness defined therebetween, the panel comprising:
 a load-bearing and vapor barrier core layer having an inner face and an opposite outer face;   an interior insulating and utility installation layer bonded to the inner face of said core layer, the interior insulating and utility installation layer comprising a plurality of channels extending from top to bottom thereof for accommodating utility lines;   an exterior sheet of a first rigid building material bonded to said interior insulating layer; and   an interior sheet of a second building material bonded to the outer face of said core layer.   
   
   
       2 . The wall panel of  claim 1  wherein the core layer comprises at least two tubular metal members and one or more interior sandwich panels extending between said two metal members, the one or more sandwich panels and the metal members having substantially the same length and thickness so as to form in combination a solid layer with two opposite flat faces. 
   
   
       3 . The wall panel of  claim 2  wherein said one or more sandwich panels comprise thermal insulating material sandwiched between two flat metal skins. 
   
   
       4 . The wall panel of  claims 3  wherein said thermal insulating material is selected from the group consisting of mineral wool, polymer foam and timber. 
   
   
       5 . The wall panel of  claim 1  wherein said insulating and utility installation layer comprises a plurality of spaced apart elongated blocks of insulating material. 
   
   
       6 . The wall panel of  claim 1  wherein said insulating and utility installation layer comprises a mattress-like body made of insulating material provided with a plurality of channels extending the entire length of said mattress-like body having openings at top and bottom edges of the body. 
   
   
       7 . The wall panel of  claim 1  wherein said exterior sheet is selected from the group consisting of a cement board, a timber board, a metal sheet and a reinforced plastic sheet. 
   
   
       8 . The wall panel of  claim 1  wherein said interior sheet is selected from the group consisting of a gypsum board, a cement board and a timber board. 
   
   
       9 . The wall panel of  claim 1  wherein said thickness is in the range of 140 to 260 mm. 
   
   
       10 . The wall panel of  claim 2  further comprising a top frame member and a bottom frame member welded to said at least two metal tubular members for forming a frame around the panel. 
   
   
       11 . A method for fabricating a building panel, the method comprising the steps of:
 forming a stack of horizontally placed building layers in a successive manner;   coating the upper surface of each layer with an adhesive before the next layer is placed thereon; and   subjecting said stack to uniform compression forces.   
   
   
       12 . The method of  claim 11  wherein said stack comprises a first sheet of a building material, a core layer, an insulating and utility installation layer and a second sheet of building material. 
   
   
       13 . The method of  claim 11  further comprising the step of incorporating a frame metal into said stack of building layers. 
   
   
       14 . The method of  claim 11  wherein said subjecting step is performed by means of a vacuum manifold. 
   
   
       15 . The method of  claim 11  wherein said subjecting step is performed by means of a compression plate. 
   
   
       16 . The method of  claim 11  wherein said compression forces are in the range of 0.2 to 0.6 Kg/cm2. 
   
   
       17 . A building component comprising at least one prefabricated wall panel as defined in  claim 1 .