Note: Descriptions are shown in the official language in which they were submitted.
CA 03145826 2022-01-04
WO 2021/007653
PCT/CA2020/050919
FACADE PANEL WITH INTEGRATED WINDOW SYSTEM
FIELD OF THE INVENTION
[001] The present invention relates to the field of construction of modular
structures. More particularly, the present invention relates to the field of
panel
systems for use in the construction of mass timber multi-storey, modular
structures.
BACKGROUND OF THE INVENTION
[002] Prefabricated facade wall panels are becoming increasingly commonly used
in construction (for example in the construction of curtain walls for multi-
storey
modular buildings) due to efficiency factors ¨ often leading to possible
reductions in
terms of construction time and/or construction costs. Prefabricated facade
panels
generally allow for very quick assembly during the construction process. This
can,
for example, allow for a quick building envelope enclosure, which among
various
advantages, can reduce the risk of water damage to the overall structure (e.g.
caused by rain).
[003] Using prefabricated facade panels in construction can be relatively
straightforward when the facade panels are used simply to construct basic wall
sections without windows/door or other such features. However, when it comes
to
using prefabricated facade panels to construct wall sections that also have
windows, doors or other complications, additional complexities and
considerations
will apply.
[004] Curtain wall systems are usually made from steel or timber as frame
constructions from many small elements. (Mass timber is increasingly being
used
in the manufacture of prefabricated facade panels for a number of reasons,
including because it is generally considered to be environmentally sustainable
and
of relatively low cost). The cavities between the frames are usually filled
with
insulation and covered with wooden boards. The complexity of this construction
makes it difficult to adapt to different window sizes and difficult to ensure
air-
tightness along all seams.
CA 03145826 2022-01-04
WO 2021/007653
PCT/CA2020/050919
[005] Further, many of the disciplines associated with such building
materials,
such as steel framing, mass timber construction, wall finishes, connectors,
insulation and window manufacturing have become increasingly specialised and
separated, resulting in high tolerance margins and limited adaptability; the
separation of these building materials disciplines, make it challenging to
integrate
such disciplines to develop prefabricated facade panels. Largely because of
these
reasons, prefabricated facade panels have not generally been used in the
construction of wall sections having windows, doors or other complication
features,
for multi-storey modular buildings.
[006] On a typical such construction project, the windows, doors, connection
hangers for insulation and various other building components are done on-site.
The mass timber façade panels and such building components are
fastened/installed in weather-permitting (sometimes challenging) conditions.
These
discrete trades arrive on-site and conduct their work according to the
generalized
instructions from manufacturers and the architectural specifications. When
components, membranes, cladding, etc. are attached, the materials themselves
may be exposed to the weather and material expansion differentials, which can
lead to poor constructability.
[007] Accordingly, it is contemplated that there could be significant
advantages to
be had in providing for a construction element wherein facade panels and such
building components are integrated together and prefabricated, and in
providing a
construction system utilising such prefabricated facade panels.
SUMMARY OF THE INVENTION
[008] In accordance With an aspect of the present invention, disclosed herein
is a
prefabricated façade panel (sometimes generally referred to herein as a
construction element) having an integrated window system. Such a facade panel
and integrated window system may have particular application for use in the
construction of curtain walls for multi-storey, modular structures or
buildings. Also
disclosed herein is a system for constructing a multi-storey building or
modular
structure using such façade panels. Also disclosed herein is a method of
constructing such a facade panel having integrated windows.
2
CA 03145826 2022-01-04
WO 2021/007653
PCT/CA2020/050919
[009] Disclosed herein is a composite construction element for building multi-
storey structures, which construction element is prefabricated and is to be
fastened/installed on the construction site.
[0010] In
accordance with an aspect of the present invention, disclosed
herein is an integrated construction element for constructing a curtain wall
for a
multi-storey building, comprising: an envelope structural subpanel, one or
more
feature elements; an insulation layer; and a cladding layer, wherein the
envelope
structural subpanel, has a top edge and a bottom edge, and comprises an upper
beam disposed substantially along the top edge and a lower beam disposed
substantially along the bottom edge, and a plurality of spacers disposed
between
the upper beam and the lower beam, wherein the upper beam, lower beam and
plurality of spacers define one or more openings for receiving the one or more
feature elements; wherein the insulation layer is attached to the envelope
structural
subpanel, and wherein the insulation layer is provided with one or more
openings
corresponding to the feature elements; wherein the cladding layer overlies the
insulation layer and is attached thereto.
[0011] In
one aspect, the feature elements may be windows, doors or
combinations thereof. In another aspect, the construction element additionally
comprises a plurality of attachment means (such as a clip and cleat system or
a
bracket system) connected to the envelope structural subpanel for attaching
the
construction element to a floor or ceiling of a building.
[0012] In
accordance with another aspect, the construction element may
additionally comprise a plurality of strapping elements for keeping the
insulation
layer in place. In accordance with one aspect, the envelope structural
subpanel of
the construction element is made substantially from mass timber. In accordance
with another aspect, the spacers abut the upper beam and lower beam. In yet
another aspect, the construction element may additionally comprise an
engagement means in the form of a tongue-and-groove joint, comprising either a
tongue or groove disposed substantially along either or both of a top edge of
the
construction element and/or of a bottom edge of the construction element,
wherein
each tongue or groove, as the case may be, of the construction element is
adapted
to matingly engage with a corresponding groove or tongue of a second
construction
3
CA 03145826 2022-01-04
WO 2021/007653
PCT/CA2020/050919
element, when the second construction element is disposed vertically adjacent
to
the construction element, thereby facilitating the engagement of the
construction
element with the second construction element. In yet another aspect, the
engagement means may be in the form of a "chicken head" joint, as is known in
the
art.
[0013] In
another aspect, the construction element may additionally comprise
one or more integrated building features for providing the multi-storey
building with
a soffit; a setback, a balcony, a parapet, a canopy, railings or combinations
thereof.
[0014] In
accordance with another aspect of the present invention, disclosed
herein is a system comprising a plurality of such construction elements
installed on
a multi-storey building in a grid-like configuration, wherein a first of the
construction
elements is provided with one or more connectors disposed proximate to a
periphery thereof, wherein the connectors secure the first construction
element to a
second construction element that is disposed horizontally or vertically
adjacently
thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[00151 Fig.
1 is an exploded perspective view of an exemplary embodiment
of the composite facade panel of the present invention.
[0016] Fig.
2 is a partially-exploded perspective view of the composite
façade panel, in accordance with one aspect of the present invention.
[0017] Fig.
3 is a partially-exploded perspective view of another embodiment
of the composite façade panel, in accordance with another aspect of the
present
invention.
Fig. 4 is a perspective view of one embodiment of the envelope
structural subpanel, in accordance with an aspect of the present invention.
[0019] Fig.
5 is a perspective view of another embodiment of the envelope
structural subpanel, in accordance with an aspect of the present invention.
4
CA 03145826 2022-01-04
WO 2021/007653
PCT/CA2020/050919
[0020] Fig.
6 is a partially-exploded perspective view illustrating a plurality of
composite facade panels being installed upon a plurality of floor slabs of a
multi-
storey building.
[0021] Fig.
7 is a perspective view illustrating various other composite façade
panels having various additional features.
[0022] Fig.
8 is a side view illustrating the engagement of vertically adjacent
composite façade panels.
[0023] Fig.
9 is a side view illustrating the configuration of several composite
façade panels across several floors of a multi-storey building.
DETAILED DESCRIPTION OF THE INVENTION
[0024] A
detailed description of one or more embodiments of the present
invention is provided below along with accompanying figures that illustrate
the
principles of the invention. As such, this detailed description illustrates
the present
invention by way of example and not by way of limitation. The description will
clearly enable one skilled in the art to make and use the invention, and
describes
several embodiments, adaptations, variations and alternatives and uses of the
invention, including what is presently believed to be the best mode and
preferred
embodiment for carrying out the invention. it is to be understood that routine
variations and adaptations can be made to the invention as described, and such
variations and adaptations squarely fall within the spirit and scope of the
invention.
For the purpose of clarity, technical material that is known in the technical
fields
related to the invention has not been described in detail so that the
invention is not
unnecessarily obscured.
[00251
Disclosed herein is a composite construction element for building
multi-storey structures. More specifically, disclosed herein is a mass timber
composite construction element for use in constructing a curtain wall for a
multi-
storey structure, which construction element is prefabricated and is to be
installed/connected on the construction site. The composite construction
element
is generally described and illustrated herein for use in the construction of a
curtain
wall for a multi-storey building (i.e. as a new build"); however, it will be
appreciated
5
CA 03145826 2022-01-04
WO 2021/007653
PCT/CA2020/050919
by one skilled in the art that the composite construction element may also be
used
(or adapted for use) in the construction of a curtain wall to retrofit an
existing multi-
storey building.
[0026]
Referring to Fig. 1, this illustrates an exploded perspective view of an
exemplary embodiment of the composite facade panel of the present invention.
The composite facade panel 10 comprises an envelope structural subpanel 20 and
a window subpanel system 30. The window subpanel 30 comprises the elements
that typically make up a curtain wall having windows, namely: one or more
windows
32; an insulation layer 34, which includes one or more corresponding openings
for
receiving the one or more windows 32; strapping 36; and a cladding layer 38.
Alternative configurations of the components of the window subpanel 32 are of
course possible. It is also contemplated that the other component layers may
be
substituted or supplemented depending on the specific requirements,
functionality
or desired specifications for the curtain wall, as will be understood by one
skilled in
the art. For example, additional layers of a vapor barrier, waterproofing,
additional
insulation, additional cladding may be added to, or used to replace one or
more of
the component layers, as may be appropriate in particular circumstances. While
not specifically illustrated in Fig. 1, it is also contemplated that such a
composite
facade panel may optionally additional incorporate one or more door elements,
e.g.
where the composite panel is used to construct a wall section for a building
(i.e.
rather than a curtain wall section). In a similar fashion as discussed above
that a
prefabricated composite facade panel can be provided that has one or more
windows integrated therein, so a prefabricated composite facade panel can also
be
provided with an integrated door or doorway, and/or windows. it is
contemplated
that other complications may also be integrated into such a composite facade
panel
(such as electrical services and mechanical services, venting structures,
etc.), as
might typically be found in a multi-storey building.
[0027] It
will be evident to one skilled in the art that such a prefabricated,
integrated facade panel system as disclosed herein will provide for advantages
in
general airtightness. There will generally be minimal tolerances between the
various component layers (e.g. given the integrated membranes) and the ease of
on-site assembly will generally reduce errors and improve quality control
issues
6
CA 03145826 2022-01-04
WO 2021/007653
PCT/CA2020/050919
that might otherwise be caused by variations in on-site workmanship and/or
caused
by difficult on-site work conditions during installation of the various
component
layers.
[0028] The composite
facade panel 10 is also provided with an attachment
means 40, for affixing the composite facade panel 10 to the structure of the
building. In one embodiment, the attachment means 40 may be in the form of a
clip
and cleat system or a bracket system (as is known in the art), by means of
which a
facade panel 10 may be installed or hung onto an upper floor, such that the
facade
panel 10 extends down one or more floors of the building. (For example, the
attachment means 40 can be configured to attach to the upper floor near the
underside of the ceiling of the upper floor or near the topside of the floor
or the
upper floor).
[0029] As mentioned
above, the composite facade panel 10 is a unitary,
prefabricated panel.
[0030] Referring to
Fig. 2, this shows a partially-exploded view of the
envelope structural subpanel 20 and the window subpanel 30, which together
make
up the composite facade panel 10. in this example, the windows 32 of the
window
subpanel 30 are shown as having a regular pattern. The envelope structural
subpanel 20 and the window subpanel 30 are affixed together to form the
composite facade panel 10, which is a unitary prefabricated construction
panel.
Fig. 3 illustrates another embodiment of the structural subpanel 20 and window
subpanel 31, which together make up the composite facade panel. In this
example,
the windows 32 in the window subpanel 31 may have an irregular window pattern.
Thus, it is to be understood that the present composite facade panel system 10
is
readily customizable in order to be adapted to different construction
requirements
and configurations.
[0031] Fig. 4
illustrates an exemplary envelope structural subpanel 20. The
envelope structural subpanel 20 comprises an upper subpanel or upper beam 22,
disposed at the top of the envelope structural subpanel 20 and extending
substantially the length thereof; a lower subpanel or lower beam 24, disposed
at
the bottom of the envelope structural subpanel 20 and extending substantially
the
7
CA 03145826 2022-01-04
WO 2021/007653
PCT/CA2020/050919
length thereof; and plurality of strengthening infill panels or spacers 26,
disposed
between the upper beam 22 and lower beam 24. Optionally, these components
may be affixed to an internal subpanel 29, such that the components are
integrated
as a single subpanel. Between the strengthening spacers 26, openings may be
provided to correspond with each of the plurality of windows 32. The primary
function of the upper beam 22, lower beam 24 and strengthening spacers 26 is
to
provide structural integrity, shear stiffness, and/or structural support to
the envelope
structural subpanel 20 of the composite façade panel 10. The upper beam 22 and
the lower beam 24 primarily provide structural support in the direction along
the
length of the envelope structural subpanel, whereas the strengthening spacers
26
primarily function to provide structural support in the direction along the
width of the
envelope structural subpanel 20. The upper beam 22, lower beam 24 and
strengthening spacers 26 may preferably be constructed from mass timber.
[0032] Fig.
5 illustrates another possible embodiment of the envelope
structural subpanel 20. As shown, in this example, the strengthening spacers
28
abut or may be affixed to the upper beam 22 and lower beam 24. These
components may be integrated together into a single subpanel. Optionally, such
components may be affixed to an internal subpanel 29 (not shown in Fig. 5).
[0033]
Referring to Fig. 6, this illustrates a plurality of composite façade
panels 10, as they may be installed upon a multi-storey building. Portions of
a
number of floor slabs 50 of a multi-storey building are shown. For example, a
first
composite façade panel 12 may be installed on a first floor slab 52, and
vertically
"hung" from the end of such floor slab, such that the first composite facade
panel
12 extends from the floor slab 52 to at least a second floor slab 54, i.e. the
floor
slab on the floor below, thus forming an external curtain wall between the
first floor
slab and the second floor slab. in this fashion, composite facade panels may
be
installed and hung from other floor slabs, thus creating a multi-storey
curtain wall
for the building. in this manner, the building may be provided with a curtain
wall,
which is affixed to the structural parts of the building (i.e. the floors),
but which is
otherwise structurally independent from the building, thus allowing the
curtain wall
to respond to movements or expansion/contraction of the building or of the
façade
panels.
8
CA 03145826 2022-01-04
WO 2021/007653
PCT/CA2020/050919
[0034]
Although not specifically illustrated, it is contemplated that the
composite facade panels may also be provided with connectors or attachment
means for horizontally connecting adjacent composite facade panels, in order
to
form a grid-like system. Optionally, composite facade panels may also be
provided
with connectors or attachment means for vertically connecting composite facade
panels With other composite facade panels disposed above or below thereto.
[0035] It
will be apparent that the composite facade panels as described
above may be used in a modularized system, for efficient assembly and
installation
of walls/curtain walls for a multi-storey building. Furthermore, the design of
the
composite facade panels is such that they can be configured/adapted and
customised for different specifications.
[0036] The
straight composite facade panel 10 described above may be
adapted or configured for various other building features or geometries. Fig.
7
illustrates a number of other types of composite facade panels having various
additional features. For example, corner facade panel 60 includes a corner
section
62, which is used for constructing a portion of a curtain wall corresponding
to a
corner of a building. Another facade panel 64 may be provided with a soffit
panel
66, and used for facade panels where a section of a building has an overhang.
Facade panel 64 may also be provided with a setback 68. A facade panel 64 may
also be provided with a balcony or parapet panel 70, where construction of
balcony/parapet is required. Other adaptations depending on the specific
construction requirement for a particular building will be apparent to one
skilled in
the art. These facade panel examples will each potentially have the same sort
of
advantages discussed previously that are applicable to the straight composite
facade panel 10; such prefabricated facade panels can be relatively quickly
and
easily assembled / connected together at a construction site, without
requiring
multiple specialist trades to each be involved at a construction site.
[0037] A
composite facade panel may also be optionally provided with a
number of external finishes or features, such as rain screens, shading screens
(canopies), railings, each of which will be constructed as to be affixed to
the
envelope structural subpanel 20 of said composite facade panel.
9
CA 03145826 2022-01-04
WO 2021/007653
PCT/CA2020/050919
[0038]
Referring to Fig. 8, this shows the ends of a first floor slab 52 and a
second floor slab 54, i.e. the ends of an upper floor and a lower floor of a
multi-
storey building. A first composite façade panel 12 is shown installed on or
'"hung'
from the first floor slab 52, via an attachment means 40. A second composite
façade panel 14 is shown installed on the second floor slab 54, on the floor
below.
The composite façade panels thus make up a section of curtain wall for the
multi-
storey building. In one embodiment, a first composite facade panel 12 may also
be
provided with engagement means on one or both of its top and bottom edges, for
engagement with the another corresponding composite panel positioned directly
above or below said first composite facade panel 12. As shown in Fig. 8, a
first
composite panel 12 is provided with tongue joint 74 running along the length
of its
bottom edge. A second composite facade panel 14 is provided with a
corresponding groove 72 running along the length of its top edge, wherein such
groove 72 is adapted to receive the tongue 74 of the first composite façade
panel.
Thus, the first composite façade panel 12 and a corresponding second composite
façade panel 14 may be matingly engaged to provide additional stability
between
the composite façade panels. Such interlocking façade panels may be weather-
stripped to seal to one another. One other advantage of such a tongue-and-
groove-type joint is that it can account for small thermal
expansion/contraction
effects or other movement effects, in or between the composite facade panels
(e.g.
caused by temperature changes, inter-storey differential movement, concrete
creep, column foreshortening and/or seismic movement). For example, in the
event a façade panel expands in the vertical direction, there is generally
sufficient
"play" within the gap between the tongue and groove joint to permit such
expansion.
[0039]
Besides the tongue-and-groove-type joint described above, other
engagement means, that are known in the art, may be used for engaging a facade
panel with another facade panel, whether directly thereabove, therebelow or
adjacent thereto. For example, a simple butt joint closed off with a gasket
around
the edges of the facade panels could be used. Another possibility is to use a
gutter
weather seal which is often referred to in the industry as "a chicken head"
detail.
[0040]
Depending on the circumstances and desired specifications, in other
CA 03145826 2022-01-04
WO 2021/007653
PCT/CA2020/050919
embodiments, a composite facade panel may also be actually attached and
secured to another vertically adjacent facade panel, such that a particular
composite facade panel does not necessarily need to be attached to or hung
from a
floor slab so securely (such as using the attachment means). An example of
such
a curtain wall configuration is illustrated in Fig. 9. A third facade panel 16
is
engaged with and attached to a second facade panel 14, such that it does not
need
to be secured in quite the same fashion to a third floor slab 56.
11
