Prefabricated structural panel, manufacturing method and structural system

Abstract

A prefabricated structural panel is for a structural construction system. The panel defines a panel plane with a peripheral edge for connections, and includes a load-bearing frame made of concrete, steel or wood substantially coplanar with the panel plane. The load-bearing frame defines a through opening transverse to the panel plane. The panel includes a blind or glass filling layer in the load-bearing frame to close the through opening. The panel is completed in an assembly line with layers of different materials assembled on both sides of the load-bearing frame and the filling layer, on an inner side of the filling element. A covering layer fixed to metal profiles defines a gap for air circulation. Layers of isolating materials create thermal and acoustic insulation on an outer side of the load-bearing frame and filling element. The prefabricated panels are assembled by a geometric interlocking coupling and form housing units.

1 . A standard prefabricated panel, made of concrete or steel or wood, provided with a structural system for constructing buildings, wherein said prefabricated panel defines a vertical or horizontal panel plane with a peripheral edge arranged for structural connections, and with at least one through opening in a direction transverse to the panel plane; the panel comprising:
 at least one filling layer housed in a load-bearing frame to close the at least one through opening;   wherein on one side a plurality of metal profiles forming a gap substantially parallel to the panel plane and a covering opposite to the filling layer are positioned, which is fastened to the metal profiles; and   on an other side of the prefabricated panel an isolating mass finished with colored plaster completes structure of the prefabricated panel.   
     
     
         2 . A prefabricated panel according to  claim 1 , wherein the filling layer comprises at least three mutually compacted and stacked wood panels placed in a direction transverse to the panel plane, wherein at least two of the panels are made of phenolic or marine wood forming a thickness between 80 mm and 120 mm. 
     
     
         3 . A prefabricated panel according to  claim 1 , wherein the load-bearing frame defines two mutually distinct through openings extending through the load-bearing frame in a direction transverse to the panel plane,
 wherein, when configured as an outer wall, the prefabricated panel comprises two blind filling layers, or   one blind filling element and one glass filling element, or   two glass filling elements housed in the load-bearing frame so that the filling layers close the through openings, or   when the prefabricated panel is configured as a slab, the prefabricated panel comprises two blind filling layers housed in the load-bearing frame so that each filling layer closes a respective through opening.   
     
     
         4 . A prefabricated panel according to  claim 1 , wherein the covering layer is formed by at least two covering sheets fixed to each other and with the profiles, in a direction transverse to the panel plane, wherein the two covering sheets are formed from two different materials. 
     
     
         5 . A prefabricated panel according to  claim 1 , wherein the load-bearing frame is formed from concrete or steel or lamellar wood, and is made as a one-piece body. 
     
     
         6 . A prefabricated panel according to  claim 1 , comprising an isolating layer connected to the load-bearing frame, opposite to the covering layer,
 wherein the isolating layer is configured to provide an outer thermal and acoustic insulation of the prefabricated panel, and   wherein the isolating layer is formed from expanded polystyrene or rock wool or wood fiber or cork or polystyrene, or a combination of expanded polystyrene or rock wool or wood fiber or cork or polystyrene, and/or   wherein the isolating layer has a thickness between 100 mm and 200 mm, and/or   wherein the isolating layer is reinforced with a plasticized, trimmed and painted mesh.   
     
     
         7 . A prefabricated panel according to  claim 6 , comprising an isolating layer support interposed between the load-bearing frame and the isolating layer,
 wherein the isolating layer support is configured to connect the isolating layer to the load-bearing frame.   
     
     
         8 . A prefabricated panel according to  claim 1 , wherein the prefabricated panel is configured as a slab and comprises a waterproofing cladding sheet hot glued onto the filling element as a base support, and comprises a raised technical floor or a floating parquet or a cement mortar screed to accommodate gluing of tiles. 
     
     
         9 . A structural system, consisting of at least two prefabricated panels connected to each other by a connection system, wherein the connection system is interposed between two prefabricated panels. 
     
     
         10 . A structural system according to  claim 9 , comprising a first connection element and a second connection element,
 wherein the first connection element is connected to one of the two prefabricated panels, and the second connection element is connected to the other of the two prefabricated panels,   wherein the first connection element and the second connection element are connected to each other by a geometric interlocking coupling.   
     
     
         11 . A structural system according to  claim 10 , wherein the insertion portion and the housing portion both define at least one fixing hole,
 wherein the connection system comprises a fixing member configured to be inserted into the fixing holes of the insertion portion and the housing portion, to fix the first connection element to the second connection element.   
     
     
         12 . A structural system according to  claim 11 , wherein the connection system comprises a support and/or spacer element,
 wherein the structural system consists of an intersection of at least three prefabricated panels, two of the prefabricated panels are connected to each other along a same panel plane, and a third prefabricated panel connected opposite or horizontal to the two prefabricated panels, wherein the spacer element defines a seat, support, interlocking and fixing of the three panels by a threaded connection, the spacer element being a section bar.   
     
     
         13 . A structural system according to  claim 1 , formed by at least six prefabricated panels connected to one another, four of the prefabricated panels are connected to one another at an angle and forming vertical walls of the structural system, and two further prefabricated panels are connected to each other in parallel and forming a treading slab of the structural system. 
     
     
         14 . A method of making a standard prefabricated panel, made of concrete or steel or wood, provided with a structural system for constructing buildings, wherein said method comprises:
 producing in series a plurality of load-bearing frames to be stored in a warehouse;   producing in series a plurality of connections to be stored in a warehouse;   producing in series a plurality of blind or glass filling layers to be stored in a warehouse;   arranging in a warehouse a plurality of layers made of different materials to complete the prefabricated panel so as to:
 position each load-bearing frame in a vertical position; 
 connect each filling layer to each load-bearing frame; 
 then connect a plurality of tubular profiles to each filling layer, respectively; 
 then fix covering layers to metal profiles; 
 fix isolating layers to the respective load-bearing frame and filler layer, reinforce the isolating layer with a plasticized, trimmed and painted mesh. 
   
     
     
         15 . A prefabricated panel according to  claim 1 , wherein the covering layer is formed by at least two covering sheets fixed to each other and with the profiles, in a direction transverse to the panel plane,
 wherein the two covering sheets are formed from two different materials, wherein one of the covering sheets is formed of fiber cement panels, while the other of the covering sheets is formed from plasterboard.   
     
     
         16 . A prefabricated panel according to  claim 6 , comprising an isolating layer support interposed between the load-bearing frame and the isolating layer,
 wherein the isolating layer support is configured to connect the isolating layer to the load-bearing frame,   wherein the isolating layer support is formed by panels made of compacted marine or plumbed wood.   
     
     
         17 . A structural system according to  claim 10 , wherein the insertion portion and the housing portion both define at least one fixing hole,
 wherein the connection system comprises a fixing member configured to be inserted into the fixing holes of the insertion portion and the housing portion, to fix the first connection element to the second connection element, and   the fixing holes are threaded, and the fixing member is a threaded member configured to be screwed into the threaded fixing holes.   
     
     
         18 . A structural system according to  claim 11 , wherein the connection system comprises a support and/or spacer element,
 wherein the structural system consists of an intersection of at least three prefabricated panels, two of the prefabricated panels are connected to each other along a same vertical plane, vertical for example, and a third prefabricated panel connected opposite or horizontal to the two prefabricated panels, wherein the spacer element defines a seat, support, interlocking and fixing of the three panels by a threaded connection, the spacer element being a section bar having a rectangular or square section.   
     
     
         19 . A method according to  claim 14 , further comprising applying a surface finish to the covering layer.