Modular building panels, method of assembly of building panels and method of making building panels

Abstract

A modular construction system is made of a plurality of panels having peripheral frame elements defining a top channel, a bottom channel and side channels. An exterior planar sheet and an interior planar sheet enclose an inner core region that is filled with an adhesive bonding material that attaches the components together.

1 . A modular construction system comprising a plurality of panels, said panels having peripheral frame elements said frame elements attached to each other at their respective opposite ends and said frame elements, said frame elements making a frame and said frame further defining a top channel, a bottom channel, and opposite side channels that face outwardly and a first planar sheet element and a second planar sheet element, and an inner core section, said inner core section filled with an insulation material, and said frame members are attached to said planar sheets and said core section, and further comprising:
 an elongate bottom strut, said bottom strut received in said bottom channel;   an elongate top strut, said top strut received in said top channel and spanning said plurality of panels, and   tie means, said tie means positioned between two adjacent panels to connect said top strut to said bottom strut and restrict the movement of said top strut and bottom strut away from one another, and   said frame further having an outwardly facing surface, an inwardly facing surface and a thickness, said thickness surrounding at least one said planar sheet element and said thickness terminating on the edge of said panels at or before the peripheral edge of one of at least one of said planar sheets elements, and   wherein, when assembled, the lateral sides of adjacent panels are in the same plane.   
     
     
         2 . The system recited in  claim 1  wherein said tie means comprise elongate threaded rods. 
     
     
         3 . The system recited in  claim 1  wherein said tie means comprise wire in tension. 
     
     
         4 . The system recited in  claim 1  wherein said channel in said frame is formed continuously around the periphery of the panel. 
     
     
         5 . The system recited in  claim 1  wherein an axial section of said top and bottom strut comprises a “U-shaped” profile. 
     
     
         6 . The system recited in  claim 1  wherein said second planar sheet is comprised of magnesium oxide. 
     
     
         7 . The system recited in  claim 1  wherein said first planar sheet is comprised of cement board. 
     
     
         8 . The system recited in  claim 1  wherein said adhesive material comprises polyurethane. 
     
     
         9 . The system recited in  claim 1  wherein said bottom strut and said top strut are parallel with one another. 
     
     
         10 . The system recited in  claim 1  wherein said panels are polygonal. 
     
     
         11 . The system recited in  claim 11  wherein said bottom and said top strut are not parallel to one another. 
     
     
         12 . The system recited in  claim 11  wherein said panels are trapezoidal. 
     
     
         13 . The system of  claim 1  further comprising providing a slat to cover the seam between two adjacent panels. 
     
     
         14 . A method of making a wall comprising securing an elongate bottom strut on a base element, positioning a plurality of panels having channels on bottom surfaces onto said elongate bottom strut, placing a top strut in a top channel provided in each said panel, positioning a tie rod between said bottom strut and said top strut in a passage formed between adjacent and abutting panels, engaging receiving and securing means in the bottom strut and securing the top of said tie rod thereby preventing said top strut from movement with respect to said bottom strut and wherein said panels comprise first planar sheet, a second planar sheet and a frame member around the periphery of said first and said second planar sheets, said frame member further comprising a thickness which surrounds said first and second planar sheets at the periphery and terminates at or before an outer peripheral edge of at least one said planar sheets, and said frame member further comprising a channel which is adapted to receive said bottom and said top strut. 
     
     
         15 . The method recited in  claim 14  wherein said panels comprise a laminate construction including a first planar sheet, a core region filled with an insulating material and a second planar sheet. 
     
     
         16 . The method recited in  claim 14  wherein said base element comprises a floor. 
     
     
         17 . The method recited in  claim 14  further comprising first setting a corner panel to said base element, wherein said corner panel extends in more than one plane. 
     
     
         18 . A modular panel comprising a plurality of frame elements, a first planar sheet, a second planar sheet and a core region filled with an insulating material,
 said frame elements comprising a top member, a bottom member and two lateral members, wherein said top and bottom members have abutting surfaces that are perpendicular to the lateral sides of said panel, said members further comprising channels, said channels running along the length of each said top, bottom and lateral members and said channels on said top and bottom members in line with channels provided on adjacent panels, and said frame members having a thickness which surrounds said panels at the periphery and terminates on the edge of said panels at or before the outer peripheral edge of said panel, and wherein said lateral sides also comprise abutting surfaces.   
     
     
         19 . The modular panel recited in  claim 18  wherein said channel is positioned in the center of said abutting surfaces. 
     
     
         20 . The modular panel recited in  claim 18  wherein said channel is offset from the center of said abutting surfaces. 
     
     
         21 . The modular panel recited in  claim 18  wherein said abutting surface further comprises two parallel strips separated by said channel and said strip elements are in the same plane and face a direction perpendicular to the lateral panels. 
     
     
         22 . The modular panel recited in  claim 18  wherein said abutting surface comprises a planar strip positioned adjacent to said channel and said panel further comprises a second planar strip, opposite said channel and parallel with said abutting surface and offset from said abutting surface thereby comprising an offset side. 
     
     
         23 . The panel recited in  claims 22  wherein said panels are used to construct a structure defining an interior space and said offset side is positioned internal to said space and said offset side is adopted to receive a tubular chase, and wherein said chase is provided with an opening accessible from an interior lateral sidewall. 
     
     
         24 . A modular construction system for assembling structure as recited in  claim 1  further comprising an elongate foam sleeve, said sleeve having means to receive said tie rods and said sleeve adapted to fit and be engaged by said lateral channel on said panels.