Layered panel and method of construction thereof

Abstract

Described herein is a layered panel for on-site modular construction of buildings. The layered panel includes a layer formed by a prefabricated cement-bonded particle board, a supporting structure and fastening elements attaching the pre-fabricated cement-bonded particle board to the supporting structure. Also described herein is a method for manufacturing the layered panel, an installation for manufacturing the layered panel and a method for the construction of buildings with a plurality of the layered panels.

1 . A layered panel for on-site modular construction of buildings, the layered panel comprising:
 a layer formed by a prefabricated cement-bonded particle board, the prefabricated cement-bonded particle board being a composite board comprising wood particles or other natural fibers and a mineral bonding agent;   a supporting structure comprising a metal grid and a perimeter frame, the perimeter frame being configured to receive and surround the prefabricated cement-bonded particle board, and the metal grid and the perimeter frame being attached to each other; and   fastening elements attaching the prefabricated cement-bonded particle board to the supporting structure.   
     
     
         2 . The layered panel according to  claim 1 , wherein the fastening elements attach the prefabricated cement-bonded particle board to the supporting structure by threading, and wherein the fastening elements comprise screws that are inserted through holes in the metal grid and threaded into the prefabricated cement-bonded particle board. 
     
     
         3 . The layered panel according to  claim 1 , wherein the fastening elements attach the prefabricated cement-bonded particle board to the supporting structure by threading, and wherein the fastening elements comprise screws that are inserted through holes in the perimeter frame and threaded into the prefabricated cement-bonded particle board. 
     
     
         4 . The layered panel according to  claim 1 , further comprising an outermost layer and an innermost layer on opposite sides of the supporting structure, and wherein the prefabricated cement-bonded particle board is the outermost layer. 
     
     
         5 . The layered panel according to  claim 4 , wherein the innermost layer comprises at least one insulating layer and a finishing layer. 
     
     
         6 . The layered panel according to  claim 4 , wherein the innermost layer overlaps only partially with the supporting structure and the outermost layer. 
     
     
         7 . The layered panel according to  claim 6 , wherein the innermost layer has a smaller surface area than the outermost layer such that it overlaps a central portion of the supporting structure and the outermost layer, while at least two side strips of the supporting structure and the outermost layer remain exposed. 
     
     
         8 . The layered panel according to  claim 7 , further comprising mounting brackets attached to the supporting structure in correspondence with the exposed side strips. 
     
     
         9 . The layered panel according to  claim 5 , wherein the insulating layer is a thermal bridge break layer. 
     
     
         10 . The layered panel according to  claim 1 , wherein the prefabricated cement-bonded particle board is a single piece with a shape and dimension to fit the perimeter frame. 
     
     
         11 . The layered panel according to  claim 1 , wherein at least part of the metal grid comprises hollow tubular members filled with a vacuum-manufactured expanded polystyrene bar. 
     
     
         12 . A method for manufacturing the layered panel according to  claim 1 , the method comprising:
 manufacturing the supporting structure comprising the metal grid and the perimeter frame;   cutting the prefabricated cement-bonded particle board according to a predetermined layout;   assembling the cut prefabricated cement-bonded particle board inside the perimeter frame of the manufactured supporting structure; and   fastening the cut prefabricated cement-bonded particle board to the manufactured supporting structure.   
     
     
         13 . A method for the construction of buildings with layered panels according to  claim 1 , the method comprising:
 erecting a building skeleton comprising load-bearing columns and beams; and   forming at least outer walls of the building skeleton by attaching layered panels to columns and/or beams of the building skeleton, and to other layered panels, with screws and/or rivets.   
     
     
         14 . The method according to  claim 13 , further comprising:
 arranging in shipping containers an installation for manufacturing the layered panel the installation comprising a first station to form the supporting structure comprising the metal grid and the perimeter frame, a second station for cutting the prefabricated cement-bonded particle board according to a predetermined layout, and a third station to receive the supporting structure and the prefabricated cement-bonded particle board from the first station and the second station, and for assembling the prefabricated cement-bonded particle board inside the perimeter frame of the supporting structure and fastening the prefabricated cement-bonded particle board to the supporting structure;   transporting the shipping containers to a desired building site;   deploying the first, second, and third stations of the installation from the shipping containers at the desired building site;   operating the first, second, and third stations of the installation to manufacture the layered panels; and   constructing the buildings with the layered panels at the desired building site.