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(11) | EP 1 070 799 A2 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | Modular panel for building prefab room structures like cabins, hotel rooms or the like, and manufacture process thereof |
| (57) An improved modular panel, suitable for the construction of prefab rooms, comprises
a plurality of layers of various materials associated thereamong, having: at least
one inner layer (11) of light-weight hydrate of calcium silicate, with a specific
weight of about 250 kg/m3; a first outer layer (15) in plastics or metal laminate; a second layer (17) made
of a containment and stiffening lathing opposed with respect to said first outer layer
(15), said inner layer (11) having a thickness equal to at least the 50% of the overall
thickness of the panel (10) . |
FIELD OF THE INVENTION
[0001] The present invention relates to a modular panel for the building of prefab units like cabins, coaches or other transport means, hotel rooms, hospital or airport lounges or the like, the manufacture process thereof and the living units implementable therewith.
[0002] More specifically, the present invention relates to a panel made of an inner layer in a fire-retarding and acoustic insulating, like the light hydrate of calcium silicate, and of a plurality of other covering and stiffening layers, the outermost one thereof being in a plastics or metal laminate. The panel according to the present invention, by virtue of structural and mechanical characteristics thereof associated to a very low specific weight, allows the easy implementation of ceiling-inclusive cabins or prefab units. The panel, having a thickness of several centimetres and a length of 10 m and over, is very handy, easily deliverable and sufficiently sturdy to bear furniture elements weighing even several tens of KGs.
[0003] In fact, also real prefab living units, easy to dispatch to and to assemble onto the building site, are implementable therewith.
STATE OF THE ART
[0004] In the building and in the transport fields, in particular in the shipbuilding and railway ones, there is a demand for building prefab and/or easily assembled units, that be light-weight and concomitantly ensuring both an adequate fire protection, using fire-retarding and non-toxic materials, and a satisfactory soundproofing, even in presence of thin thicknesses.
[0005] To this end, specifications regarding the mandatory features and the technical parameters used for the implementation of such units have been issued.
[0006] In the art, it is known to build walls and ceilings of such units using laminated composite prefabricated panels, usually secured thereamong with suitable joint means for forming living units.
[0007] However, either such panels are made in materials that, though remarkably light-weight possess limited structural and mechanical properties, hence necessarily having to be anchored to a heavy and uneconomical load bearing metal structure, or in more consistent materials, hence being heavy-weight, unhandy and highly expensive.
[0008] In order to overcome these drawbacks and to obtain further advantages, the modular panel according to the present invention has been developed.
DESCRIPTION OF THE INVENTION
[0011] An object of the present invention is to provide a modular panel light, fire-retarding, sturdy, easy to manufacture and to process and of top structural and aesthetic qualities.
[0012] A further object of the present invention is to build, with the panel according to the invention, cabins or other living units, for immovable or movable installations, like the ships, the coaches, or any other transport means that be light-weight, of easy assembly and servicing.
[0013] In accordance to the above objects, the panel according to the present invention comprises at least one inner layer of light-weight hydrate of calcium silicate having a specific weight of about 250 kg/m3, a first outer layer in metal or plastics laminate, a second layer made of a containment and stiffening lathing opposed with respect to the first outer layer, wherein the thickness of the innermost layer equals at least the 50%, and advantageously the 80%, of the overall thickness of the panel.
[0014] According to another feature of the invention, the process for manufacturing modular panels for the building of prefab units like cabins, coaches or other transport means, hotel rooms, hospital or airport lounges or the like, comprises the steps of:
- feeding an inner layer of light-weight hydrate of calcium silicate, possibly provided with surface notchings, grooves and/or stiffening members, to a press;
- depositing a layer of potassium silicate on each plane surface of the inner layer;
- depositing a layer of sizing resin on each potassium silicate layer;
- feeding from opposite parts with respect to the inner layer, upstream of the press, an outer laminate layer and a containment and stiffening lathing; and
- pressing the various layers at the press.
[0015] According to another feature of the invention, the prefab living unit, like cabins, coaches or other transport means, hotel rooms, hospital or airport lounges or the like, comprises side walls, one rear wall, one front wall and one ceiling, all built with modular panels according to the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The above features and other features of the present invention will be hereinafter made apparent in the description of a preferred embodiment, given by way of example and not for limitative purposes, with reference to the annexed drawings, wherein:
- Fig. 1 is a perspective and sectional view of a section of the modular panel according to the present invention;
- Fig. 2 is an illustrative diagram of a plant for the manufacture of modular panels according to the present invention;
- Fig. 3 is a schematic perspective view of a cabin implementable with modular panels according to the present invention;
- Fig. 4 is a top plan view of the cabin of Fig. 3;
- Fig. 5 is a detail of a modular panel assembled according to a predetermined configuration;
- Fig. 6 is the detail of Fig. 5 prior to the assembly;
- Fig. 7 is a schematic front view of a modular panel associated to supporting stirrups;
- Fig. 8 is a schematic top plan view of several modular panels connected thereamong;
- Fig. 9 shows several modular panels connected thereamong and the related fastening means.
DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION
[0017] Referring to Fig. 1, a modular panel 10 according to the present invention comprises a first inner layer 11, centrally arranged, having a thickness of about 20 mm, in light-weight hydrate of calcium silicate, manufactured in an autoclave starting from silica sands, hydrated lime and small percentages of other additives, like, e.g., cellulose fibre, having a remarkably low specific weight of about 250 kg/m3.
[0018] Onto both surfaces of the inner layer 11, that is porous and completely fire-retarding, yet, due to its composition, also brittle, a potassium silicate layer, 12, 13, respectively, is deposited, working as an adhesive or «primer». The potassium silicate is a non-toxic and fire-retarding material as well.
[0019] By means of a sizing resin layer 14, to the front potassium silicate layer 12, an outer layer 15 in aluminium, having a thickness of about 0.7-1 mm and defining the visible surface of the panel 10 itself, is secured.
[0020] Onto the rear potassium silicate layer 13, by means of a sizing resin layer 16, a containment and stiffening lathing 17, in plastics or glass fibre, having a thickness of about 0.5-0.7 mm and with biaxially or multiaxially arranged fibers, is secured.
[0021] The thickness of the inner layer 11 equals the 80% of the total thickness of the panel 10, even though a 50% thereof suffices.
[0022] According to a variant, any laminated element may be secured in lieu of the aluminium layer 15, made of synthetic as well as natural materials, even special ones, provided they be fire-retarding, non-toxic, scratch-and abrasion-resistant, and easy to wash. In this case, between the layer 14 and the resin layer 12 a second multiaxial stiffening lathing 17 (not shown in the drawings) is suitably interposed, the outer laminate being secured thereto with another sizing resin.
[0023] Both the lathings 17 and the resins 14 and 16 are made of non-toxic, fire-retarding and/or extinguishing materials, easily found on sale.
[0024] The resins 14 and 16, being elastic, carry out an acoustic insulating function as well, thus contributing to increase the acoustic insulation property of the panel 10.
[0025] According to a feature of the present invention, during the manufacturing step of the panel 10, internal ductings 20 could optionally be performed inside the layer 11, for easily laying electric cables, tubing or the like, and/or for inserting stiffening metal plates 21, to which any item or furniture could be secured.
[0026] On purpose, the outer surface of the lathing 17 is left raw, in order to possibly secure thereto, at the manufacturing stage of the panel 10 or thereafter, outer ductings 25 and/or outer stiffening members 26, with lathing strips 27, similar to the lathing 17, interposed with a resin layer 28 equivalent to the layers 14 and 16.
[0027] According to a further feature of the present invention, the outer surfaces of the inner layer 11 are provided with notchings 29, formed at the panel forming stage, e.g., by milling, that could be obliquely, horizontally or vertically (i.e., as depicted in Fig. 1) arranged.
[0028] The notchings 29 are acoustic-insulated and can assume the most suitable shapes, as well as being more or less spaced thereamong, depending on the desirable soundproofing ratio.
[0029] The panel 10 hereto described has an overall weight of about 10 Kg/m2, hence being remarkably light-weight as compared to the known panels. Nevertheless, it has optimal structural and mechanical characteristics, to the extent that an over 8 m long, 2.8 m high wall could be built with a single panel 10, with no need of joints or additional external struts.
[0030] Moreover, the use of inorganic materials entails that the features of the panel 10 remain unaltered over a remarkably protracted period of time.
[0031] Further, the panel 10 is easily manufacturable, and therefore the manufacturing costs thereof are quite reasonable.
[0032] In fact, the various layers constituting the panel 10 merely need to be fed through the opposed members 30 and 31 of a press 32 of known type, a predetermined orthogonal force being applied thereto.
[0033] In particular, the inner layer 11, provided with the notchings 29 and possibly with the ductings 20 and the stiffening plates 21, is linearly fed to the press 32 by feeding roller means 33, whereas the aluminium layer 15 and the lathing 17 are fed by corresponding bobbins 34 and 35 onto which the latter are wound.
[0034] The potassium silicate for forming the layers 12 and 13 is deposited by devices 36 and 37 provided for the purpose, opposed with respect to the inner layer 11, whereas the sizing resin for forming the layers 14 and 16 is deposited by devices 38 and 39, provided for the purpose and likewise opposed with respect to the inner layer 11.
[0035] Apparently, the panel 10 is particularly suitable for the building of living units of prefabricated type, like, e.g., cabins, coaches or other transport means, hotel or tourist resort rooms, hospital or airport lounges, or for any other use.
[0036] Referring to Figs. 3 and 4, a prefab living unit 40, e.g. a cabin made of modular panels 10, is disclosed by way of example and not for limitative purposes.
[0037] The cabin 40 is substantially parallelepiped-shaped, and it comprises an living room 41 and a bathroom 42, also called hygiene box, formed at a corner of the living room 41, near the entrance door 43.
[0038] The cabin 40 mainly consists of two side walls 44 and 45, parallel therebetween, one rear wall 46, inside which a window 47 is formed, one front wall 48, inside which the opening for the door 43 is formed, and one ceiling 49. Accordingly, the floor is not provided, as it could be set or formed at will onto the installation site of the cabin 40.
[0039] The front portions 44a and 45a of the side walls 44 and 45 and the entire front wall 48 are advantageously formed with a single panel 10a, suitably bent and connected with angles provided for the purpose.
[0040] The remaining portions 44b and 45b of the side walls 44 and 45 are formed each with a single panel, 10b and 10c, respectively. Likewise, the entire rear wall 46 is formed with a single panel 10d.
[0042] Moreover, with a single panel 10h, an inner wall 50, partitioning the living room 41 from the bathroom 42 and provided with an opening 51 for a corresponding inner door 52, is formed.
[0044] The panels 10a-10h, together with the aluminium layer 15 thereof, face the inside of the cabin 40, whereas the lathing layer 17 thereof lies outwards of the latter.
[0045] In fact, known suitable walls or covering panels are provided to be externally arranged onto the cabin walls.
[0046] By virtue of the metal stiffening plates 21, to each of the panels 10 suspended furniture, even weighing several tens of KGs could smoothly be coupled.
[0047] Several details of a panel 10, formed in a desirable shape, with positive as well as negative corners with respect to the initial plane of the panel 10 itself, are shown in Figs. 5 and 6.
[0048] At each corner a milling 53 corresponding to the width of the corner itself is carried out, without cutting off the outermost layer, that could be the one in aluminium 15 or that of the lathing 17. The panel is bent at the milling 53 and stiffened with metal angles 54, suitably sized with resin and other glass fibre lathing strips.
[0049] Each panel 10 (Fig. 7) is apt to be spaced from the floor and from the ceiling 49 of the cabin 40 with shaped metal stirrups 55 provided for the purpose.
[0050] In case two adjacent panels 10 are to be coupled, guide members 56 provided for the purpose are used, shown in Fig. 8, whereas for interlocking the former in a determined position metal stakes 57 (Fig. 9), apt to be inserted in metal bushings 58, in turn housed within transverse holes of the panels 10, are used. The metal stakes 57 are apt to cooperate with the fastening screws 59 and with axial sealing members 60.
[0051] In case of accidental damages to the outer layer or to the structure as a whole, the hereto described panels 10 can be repaired or replaced in an easy, quick and cost-effective way, since any one portion thereof can easily be cut out, removed and replaced with an analogous new portion that is fastened to the pre-existing structure.
[0052] Of course, to the hereto described panel 10, to the manufacturing process thereof, and to the cabin 40, modifications or additions of components may be effected without departing from the scope of the present invention.
[0053] Moreover, although the present invention has hereto been described with reference to some specific embodiments, of course those skilled in the art may effect several other panel or cabin embodiments equivalent to the above-described ones, all however comprised within the scope of the present invention.
1. A modular panel for the construction of prefab rooms, comprising a plurality of layers
of various materials associated thereamong, characterised in that said plurality of
layers comprises: at least one inner layer (11) of light-weight hydrate of calcium
silicate; a first outer layer (15) in plastics or metal laminate; a second layer (17)
made of a containment and stiffening lathing opposed with respect to said first outer
layer (15), said inner layer (11) having a thickness equal to at least the 50% of
the overall thickness of the panel (10) .
2. The modular panel according to claim 1, wherein light-weight hydrate of calcium silicate
has a specific weight of about 250 kg/m3.
3. The modular panel according to claim 1, wherein said inner layer (11) is centrally
arranged between said first outer layer (15) and said lathing (17), said inner layer
(11) having a thickness equal to at least the 80% of the overall thickness of the
panel (10).
4. The modular panel according to claim 1, wherein, between said inner layer (11) and
said first outer layer (15), at least one layer (12) of potassium silicate working
as adhesive and one layer (14) of sizing resin are interposed.
5. The modular panel according to claim 1, wherein said lathing (17) is in multiaxial
glass fibre and forms the outer layer opposed to said first outer layer (15) and,
between said inner layer (11) and said lathing (17), being interposed at least one
potassium silicate layer (13), working as adhesive, and one sizing resin layer (16).
6. The modular panel according to claim 4 and 5, wherein the thickness of said inner
layer (119) is 20 mm, the thickness of said first outer layer (15) is in the range
from 0.7 mm to 1 mm, the thickness of said lathing (17) is in the range from 0.5 mm
to 0.7 mm, and the thickness of each of said potassium silicate layers (12, 13) and
of said resins (14, 16) is of several tenths of millimetre.
7. The modular panel according to claim 1, wherein, in said inner layer (11), internal
ductings (20) are formed, and/or metal stiffening plates (21) are inserted.
8. The modular panel according to claim 5, wherein the outer surface of said lathing
(17) is left raw, external ductings (25) and/or outer stiffening members (26) being
securable to said lathing (17) at the manufacturing stage of the panel (10) as well
as thereafter, with lathing strips (27) interposed with a further sizing resin layer
(28).
9. The modular panel according to claim 1, wherein the outer surfaces of said inner layer
(11) are provided with obliquely, horizontally and/or vertically arranged acoustic-insulating
notchings (29).
10. A process for manufacturing modular panels for the building of prefab units like cabins,
hotel rooms or the like, comprising a plurality of layers of various materials associated
thereamong, characterised in that it comprises the following steps:
* feeding to a press(32) an inner layer (11) in light-weight hydrate of calcium silicate, possibly provided with surface notchings (29), ductings (20) and/or stiffening members (21) ;
* depositing a potassium silicate layer (12, 13) on each plane surface of said inner layer (11);
* depositing a sizing resin layer(14, 16) on each potassium silicate layer (12, 13);
* feeding from opposite parts with respect to said inner layer (11), upstream of said press (32), an outer layer of laminate and a containment and stiffening lathing (17);
* pressing said layers (11-16) at said press (32).
11. The process according to claim 10, wherein, in order to form corners in said panel,
firstly a milling (53) corresponding to the width of the corner itself is carried
out at each corner, without cutting off the outermost layer that could be the laminate
(15) or the lathing (17) one, then the panel is bent at each milling (53) and stiffened
with metal angles (54), suitably sized with resin and other glass fibre stiffening
lathing strips.
12. A prefab living unit, like cabins, hotel rooms and the like, comprising side walls
(44, 45), one rear wall (46), one front wall (48) and a ceiling (49), characterised
in that at least one of said walls and/or said ceiling are formed with modular panels
(10) according to any one of claims 1 to 9.
13. The living unit according to claim 12, wherein the front portion (44a and 45a) of
said side walls (44 and 45) and the entire front wall (48) are formed with a suitably
bent single panel (10a).
14. The living unit according to claim 12, wherein each rear portion (44b and 45b) of
said side walls (44 and 45) is formed with a single panel (10b, 10c).
15. The living unit according to claim 12, wherein said rear wall (46) is formed with
a single panel (10d).
16. The living unit according to claim 12, wherein said ceiling (49) is formed with at
least two panels (10e, 10f) adjacent therebetween.
17. The living unit according to claim 12, wherein an inner wall (50) apt to partition
a living room (41) from a bathroom (42) is formed with a single panel (10h).
18. The living unit according to claim 12, wherein said panels (10a-10h) face, together
with said first outer layer (15), the inside of the unit itself, whereas they face
the outside thereof with said lathing layer (17).
19. The living unit according to claim 19, wherein the panels (10) forming said walls
are apt to be spaced from the floor and/or from said ceiling (49) with shaped metal
stirrups (55).
20. The living unit according to claim 12, wherein, for each joint between two adjacent
panels (10), suitable metal guide members (56), for interlocking the former in a predetermined
position metal stakes (57) apt to be inserted in metal bushings (58), in turn housed
in transverse holes, being used.
21. The living unit according to claim 20, wherein said metal stakes (57) are apt to co-operate
with fastening screws (59) and with axial sealing members (60).