Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: PREFABRICATED BUILDING PANEL AND
METHOD OF MAKING THE SAME
FIELD OF THE INVENTION
The present invention relates to a wall stud
construction system covered by a cement substrate. The
construction system can be used to manufacture
prefabricated building panels at a remote location or to
manufacture walls on site. The construction system provides
versatility and is cost effective.
BACKGROUND OF THE INVENTION
A number of prefabricated panels have been
proposed, as to address the need for more efficient, low
cost housing and the ability to construct various dwellings
using unskilled labour.
Some systems have used extruded hollow sections of
plastic to define interior and exterior surfaces of a panel
and then fill the hollow cavities of the extrusion on site.
Another approach is to build sections of an entire wall.
and ship these basically finished wall panels. There
r~m~' n.s a need for a more cost effective and easily varied
building panel system.
SUMMARY OF THE INVENTION
A rectangular prefabricated building panel,
according to the present invention, comprises a lath
substrate attached to a perimeter metal frame with the lath
reinforcing a scratch coat of a cement type material,
preferably reinforced with glass fibers. The panel is
produced by providing temporary back support for the lath
and scratch coat during application of the scratch coat to
the lath. The scratch coat and lath are self-supporting
once the scratch coat has cured.
It is also possible to build the wall on site. In
this case the stud frame is built, the lath is attached
thereto, the vapour or air barrier is attached, the
temporary back support is positioned and the scratch coat
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is applied. Shortly thereafter the temporary back supports
are removed.
According to an aspect of the invention, the
perimeter frame is defined by metal channels.
According to a further aspect of the invention, the
panel has a number of studs intermediate the height of the
panel which support the lath.
According to a further aspect of the invention, the
panel includes means for maintaining the spacing of the
studs, particularly for use during shipping to avoid
bending of the combined lath and scratch coat.
According to an aspect of the invention, the panel
includes guide members projecting outwardly from the
scratch coat with the guide members collectively defining a
predetermined depth used to assist in applying a finish
coat to the panel.
According to a further aspect of the invention, a
vapour or air barrier is positioned between the studs and
the scratch coat.
A method of manufacturing a wall or panel
structure, according to the present invention, comprises
providing a perimeter frame of metal channels and metal
studs with at least some of the studs being intermediate
the width of the structure and extending the length
thereof, attaching a lath substrate to one face of the
metal studs, positioning temporary support members between
the studs, applying a cement type scratch coat to the lath
substrate supported by the temporary support members, the
studs and the lath substrate, allowing the scratch coat to
dry and stiffen, and removing the temporary support
members.
With this method and panel, the backing members
necessary for supporting the scratch coat during the
application thereof are removed when the scratch coat has
cured sufficiently to be self-supporting. In this way, the
cost for these support members in each final panel is
avoided and the support members are reused.
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Bracing of the studs avoids buckling or racking of
the scratch coat during shipping of a panel and, if
necessary, when installed. The panel during installation
is reinforced by an interior surface, such as drywall,
applied to the panel. The scratch coat even if it cracks
during shipping is maintained by the lath and is covered by
a final coat when the panel is finally installed.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown in
the drawings, wherein:
Figure 1 is a sectional view showing a portion of a
panel being manufactured;
Figure 2 is a partial perspective view of a
finished building panel with the bracing removed;
Figure 3 is a partial perspective view of the panel
prior to application of the scratch coat; and
Figure 4 is a partial perspective view illustrating
how temporary supports are maintained in place to support
the scratch coat.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The general concept of the prefabricated building
panel is shown in Figures 1, 2, 3 and 4. The building
panel 50 includes on the rear surface thereof a number of
metal studs 11 which are captured at the base of the panel
and at the top of the panel by opposed 'U' shaped members
15. The metal studs 11 and the channel members 15
cooperate to form a frame about the panel and to reinforce
the panel at intermediate positions due to a number of the
studs being intermediate the frame. The panel 50 has a
scratch coat 3 which forms one surface of the panel and
this scratch coat is made up of a cement type material,
preferably reinforced with glass fibers, with a lath type
substrate 4 which has been previously secured to the studs.
The back of the panel, which is the 'up' side shown in
Figures 2 and 4, is open and will be sent to the building
site typically in this manner. A vapour or air barrier 1
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is preferably provided between the studs and the scratch
coat. This barrier also serves to protect the temporary
supports from the scratch coat when it is applied.
Additional reinforcing members 55 for shipping are
used to maintain the spacing of the studs 11 and to avoid
bending or flexing of the panel frame and thereby protect
scratch coat 3. The reinforcing members 55 pass through
ports 57 in the studs and frames. These reinforcing
members 55, as shown in Figure 4 press wedges 10 against
temporary supports 8. These supports 8 and wedges 10 are
removed after curing of the scratch coat 3.
The front face 52 of the panel includes a plastic
or metal 'J' mold 2 installed on the perimeter frame of the
panel to allow a final coat to be applied in a level manner
and to protect the edge thereof. In addition, a further
intermediate guide 6 is attached to the intermediate studs
and is partially embedded in the scratch coat. The
intermediate guide 6 simplifies levelling of the final coat
which will be applied in the field. Various ports 57 are
provided in the studs and in the channels for allowing
securement of panels in the field or to provide ports
through which wiring can pass. The panels in the field are
assembled on footings and are grouped to define a wall. A
finished coat is then applied to the exterior of the
secured panels. The members 2 and 6 simplify the levelling
of the final coat which provides an uninterrupted final
surface, except for any expansion joints required therein.
The interior of the panels will still be open and any
insulation can be added on site. The open backed panels
are easily wired on site. The metal studs 11 include ports
57 along their length and these ports are aligned to allow
reinforcing member 55 (Figure 4) to be inserted
therethrough to provide stiffening during the manufacturing
of the panel and during shipping of the finished panel.
In order to manufacture the panel of Figure 2, it
is required to provide support for the scratch coat
intermediate the studs 11. Temporary reusable support
members 8, shown in Figure 1, provide this support and are
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shown in Figure 1 being supported above the stiffener or
reinforcing member 11 which passes through the ports and
the channel. Wedge blocks 10 position the temporary
support in the desired position, and as shown, the
temporary supports are generally flush with the face of the
channels. It can be seen that the lath substrate 4,
preferably of metal or nylon, is positively attached to the
channels by rivets or screws and preferably has plastic
washers to distribute the force of attachment to the
substrate. The guides 6 and the perimeter frame 8 are also
attached to the studs. The scratch coat can be applied
with the temporary supports 8 in position, as shown in
Figure 1, and the scratch coat is then allowed to dry and
stiffen. Once the scratch coat has stiffened, the panel
does have significant structural stability due to the
scratch coat and due to the channels and the integration of
these components. The structural integrity is further
improved by maintaining the spacing of the studs and this
can be accomplished by the stiffener, shown as 9 and 55.
The temporary supports 8 can be removed, as they are no
longer necessary to directly support the scratch coat.
These supports are then reused.
In some cases, it is desirable to provide an air or
vapour barrier and such a barrier is shown as 1 in Figure
1.
With the structure as shown in Figure 1, it can be
seen that the panel can be made in substantial widths which
is a significant benefit if manufactured as a wall of the
building or is manufactured as large panels onsite and then
put in position. The size and configuration of the panels
can be preengineered and designed for the specific
application. The back surface of the panels are fully open
to allow wiring and/or the addition of any insulation
materials, if necessary, and the final interior surface can
be attached to the studs on site. The temporary stiffeners
9 can provide protection to the panel during the shipping
thereof. It has been found that the reusable aspect of the
temporary supports 8 and allowing this material to be
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removed from the finished panel significantly reduces the
costs of the panel or wall. The panel is not particularly
vulnerable to damage during shipping and the final panel
will be further reinforced by the finished layer, which is
applied to the exterior of the building panels on site and
by an interior surface.
This particular panel is easily manufactured at an
offsite location and shipped to a job site. It is also
possible to manufacture the panel onsite, if desired, using
a production line type process. It is also possible to
manufacture on site as part of the building by assembly of
the stud frame of the building and then apply the other
components.
The panel or wall has been primarily described with
respect to metal studs and metal channels, however, wood
studs, and wood top and bottom plates can also be used.
Basically, the studs provide the support for the scratch
coat, and therefore, the studs and frame can be of any
suitable material.
Although various preferred embodiments of the
present invention have been described herein in detail, it
will be appreciated by those skilled in the art, that
variations may be made thereto without departing from the
spirit of the invention or the scope of the appended
claims.
