Technical field of the invention

The present invention relates to wall systems for buildings.

Background of the invention

Today, it is well known to manufacture and use prefabricated panels in building systems. The panels may be provided to form walls, roof, or floors of a building to be constructed, and may thus be provided with different materials and structures in order to fit their purpose. Known wall panels may be difficult to install and adjust relative to the flooring.

It is an objective of the present invention to provide an improved wall system for buildings that is easy to install and to adjust relative to the flooring or foundation.

Description of the invention

One aspect relates to a modular wall system comprising:

- a base unit adapted for being mounted to a floor or a foundation of a building; and

- a wall panel with a top, a bottom adapted for being mounted to the base unit, a first end, and a second end; wherein the bottom of the wall panel comprises an elongate cavity or groove extending along the length of the wall panel; wherein the base unit is configured as an elongate profile element extending in a longitudinal direction and having a first end, a second end, an upper part adapted for engaging with the cavity or groove of the wall panel, and a lower part adapted for engagement with said floor or foundation, wherein the upper part has a triangular or trapezoidal crosssection.

The inventor of the present invention has developed a modular wall system comprising a base unit that functions as a guide, e.g., a guide rail or guide pin, during the installation of the wall panel. The wall panel is configured to engage with or surround an upper part of the base unit. The bottom of the wall panel comprises an elongate cavity or groove extending along the length of the wall panel. The elongate cavity or groove functions, together with the upper part of the base unit, as a guide during installation of the wall panel. After installation, both the upper part of the base unit and the elongate cavity or groove functions as a locking mechanism preventing the wall panel from displacing from its intended position.

The mounting operation is initiated by placing the base unit (the elongate profile element) on a floor, terrain deck, or foundation. Optionally, it is leveled, e.g., using leveling holes formed therein for horizontal alignment of the elongate profile element. The base unit is then attached to the floor, terrain deck, or foundation, e.g., via mounting holes, such as bolt holes, formed therein. After levelling, voids may be present below the base unit. These voids are optionally filled with a casting material, such as mortar, expanding concrete, a curable polymeric composition, or the like, to ensure the correct force transmission between the wall panels and the floor, terrain deck, or foundation. A sealant, such as rubber, or silicone (elastomeric sealants), may be applied to the base before the wall panels are mounted thereto.

The base unit is preferably produced in a strong, rigid, and dimensionally stable material, such as polyethylene, polypropylene, POM, or the like, that ensures a durable solution equivalent to the lifetime of the building. In addition, the use of a polymeric material ensures that moisture from the floor, terrain deck, or foundation, will not reach the wall panels. The base unit may preferably be shortened as needed with ordinary tools. For relatively long wall sections, multiple base units may be needed. The base units may typically be of a length within the range of 50-400 cm, and the width may typically be within the range of 5-20 cm. The height of the base unit may typically be within the range of 5-50 mm. The joint between two base units should preferably be sealed with a suitable sealant.

In one or more embodiments, the upper part of the base unit is shaped as a) a triangular prism with its base facing the lower part of the elongate profile element, or b) a trapezoidal prism with its relatively largest base of the two bases facing the lower part of the elongate profile element.

In one or more embodiments, the upper part of the base unit is shaped as a triangular prism with its base facing the lower part of the elongate profile element. This shape has proven particularly suitable for the upper part’s function as a guide. Preferably, the wall panel’s elongate cavity or groove has the same shape.

In one or more embodiments, the upper part of the base unit is shaped as an isosceles triangular prism with its base facing the lower part of the elongate profile element. This shape has proven particularly suitable for the upper part’s function as a guide. Preferably, the isosceles triangular prism is a right isosceles triangular prism. Preferably, the wall panel’s elongate cavity or groove has the same shape.

In one or more embodiments, the lower part of the elongate profile element, i.e., the base unit, is relatively wider than the upper part of the elongate profile element. This embodiment leaves space in the lower part for holes for fastening and/or leveling means.

In one or more embodiments, the lower part of the elongate profile element comprises leveling holes for horizontal alignment of the elongate profile element, and/or mounting holes, such as bolt holes, adapted for use for fastening the elongate profile element to a floor or a foundation of a building. The wall panels are preferably mounted to one another, to a roof construction, and/or to the floor construction, terrain deck, or foundation by fastening means, such as bolts and brackets.

In one or more embodiments, the first end and/or the second end of the wall panel is configured as an end-to-end overlap joint (lap joint), preferably a half lap joint, a scarf joint, or a bevel lap joint.

In principle, the wall panel may be made of any suitable material. Preferably, the wall panel is made of cross-laminated timber.

In one or more embodiments, the width of the wall panel is the same as the width of the lower part of the elongate profile element.

The wall panel’s top, bottom, first end, and/or a second end may be provided with a joint seal, such as one or more bands of polymeric foam seal, e.g., to prevent the formation of cracks during expansion or contraction of the joints.

In one or more embodiments, the space(s) between said subunits are of a length within the range of 2-5 cm.

In one or more embodiments, the length of each subunit is within the range of 20-50 cm.

In one or more embodiments, the lower part of the base unit has a width of within the range of 75-200 mm.

In one or more embodiments, the upper part of the base unit has a width of within the range of 20-40 mm.

In one or more embodiments, the wall panel’s bottom is provided with a joint seal, such as one or more bands of polymeric foam seal.

In one or more embodiments, the wall panel’s first and/or second ends and/or top is provided with a joint seal, such as one or more bands of polymeric foam seal.

In one or more embodiments, the upper part of the base unit is divided into spaced apart multiple subunits, the space(s) between said subunits adapted for receiving fastening means, such as bolts or screws, adapted for use for fastening the base unit to the floor or foundation.

A second aspect relates to a method for producing a wall system comprising: a) providing one or more base units according to the present invention; b2) mounting said one or more base units to a floor construction, a terrain deck, or a foundation by fastening means; c) providing one or more wall panels according to the present invention; d) mounting said one or more wall panels to said one or more base units, while using said one or more base units as a guide during said mounting operation; and e) fastening said one or more wall panels to a roof construction, and/or to the floor construction, terrain deck, or foundation by fastening means, such as bolts and brackets.

A third aspect relates to the use of one or more base units according to the present invention for producing a wall system of wall panels, said wall panels comprising an elongate cavity or groove extending along the length of the wall panel.

As used in the specification and the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from "about" or "approximately" one particular value and/or to "about" or "approximately" another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about", it will be understood that the particular value forms another embodiment.

It should be noted that embodiments and features described in the context of one of the aspects of the present invention also apply to the other aspects of the invention.

Brief description of the figures

Figure 1 is a cross-sectional view of a modular wall system according to the present invention.

Figure 2 is a close-up view of Figure 1 .

Figure 3 is a perspective view of a part of a base according to the present invention.

Figure 4 is a longitudinal cross-sectional view of a base according to the present invention.

Figure 5 is a longitudinal cross-sectional view of a base according to the present invention.

Figure 6 is a top view of six exemplary bases according to the present invention.

Figures 7A and 7B are perspective bottom views of a wall panel according to the present invention. Figures 8A and 8B are perspective top views of a wall panel according to the present invention.

Figure 9 is a transverse cross-sectional view of five base units according to the present invention with a wall panel mounted thereon.

Figure 10 is a transverse cross-sectional view of a base unit according to the present invention with a wall panel mounted thereon (partition wall).

Figure 11 is a transverse cross-sectional view of a base unit according to the present invention with a wall panel mounted thereon (load bearing wall).

Figure 12 is a transverse cross-sectional view of a base according to the present invention with a wall panel mounted thereon (load bearing wall).

Figure 13 is a transverse cross-sectional view of a base according to the present invention.

Figure 14 is a transverse cross-sectional view of a base according to the present invention.

Figures 15A and 15B are exemplary illustrations of how to connect wall panels according to the present invention.

Detailed description of the invention

The invention is not limited to the embodiment(s) illustrated in the drawings. Accordingly, it should be understood that where features mentioned in the appended claims are followed by reference signs, such signs are included solely for the purpose of enhancing the intelligibility of the claims and are in no way limiting on the scope of the claims.

Figure 1 shows a cross-sectional view of a modular wall system 100 according to the present invention. The modular wall system 100 is here shown used as the inner wall section of a timber frame wall. The timber frame wall is here further shown with a timber frame section 200 with integrated insulation slabs (cavity insulation), and a panel board section 300. Depending on the position of the timber frame wall in the building, other sections may be placed in front of the panel board section 300, or the panel board section 300 may be exchanged with other types of wall sections. Figure 2 is a close-up view of Figure 1 , where the modular wall system 100 can be seen comprising a base unit 110 adapted for being mounted to the foundation 400 of a building, and a wall panel 120 with a bottom adapted for being mounted to the base unit 110.

The base unit 110 is configured as an elongate profile element extending in a longitudinal direction (see Figures 3-6). The base unit 110 comprises an upper part 112 adapted for engaging with a cavity or groove 122 (see Figures 7A and 7B) of the wall panel 120, and a lower part 114 adapted for engagement with the foundation 400. The upper part 112 has a triangular cross-section. The upper part 112 is configured as a triangular prism with its base facing the lower part 114 of the elongate profile element. The upper part 112 is divided into spaced apart multiple subunits 112A, 112B (see Figures 4-6) to make space for mounting holes 130 (see Figure 14), such as bolt or screw holes, adapted for use for fastening the base unit 110 to the foundation 400. The bolts 135 may e.g., be seen in Figures 3-5, 12, and 14. The spaces 113 between the subunits 112A, 112B is adapted for receiving fastening means 135, here bolts, adapted for use for fastening the base unit 110 to the floor or foundation 400. The spaces 113 are also present to easier shorten a base unit for a specific purpose as less material will need to be cut in these positions. In other embodiments, bolt mounting holes may be made directly within the sides of the upper part and/or in the lower part. Furthermore, the lower part 114 of the base unit 110 may comprise leveling holes 140, such as levelling bolt holes, for horizontal alignment of the base unit 110 as shown in Figure 14. The adjustment bolts 145 for use in the levelling operation may e.g., be seen in Figures 3-4, 10-11 , and 14. Figure 14 is a transverse cross-sectional view of the base unit 110 between two spaced apart subunits of the upper part 112. Figure 13 is a transverse cross-sectional view of the base unit 110 through a subunit of the upper part 112. Figure 5 shows an embodiment without leveling holes, where the user uses traditional wedges 500 for levelling the base unit 110. After levelling, voids may be present below the base unit 110. These voids are optionally filled with a casting material 600, such as mortar, expanding concrete, a curable polymeric composition, or the like, to ensure the correct force transmission between the wall panels and the floor, terrain deck, or foundation.

Figure 6 shows six exemplary bases according to the present invention with shown widths and lengths.

Figure 9 shows a transverse cross-sectional view of five exemplary base units 112, 114 according to the present invention with a wall panel 120 mounted thereon. The upper part 114 of the base unit is shaped as an isosceles triangular prism. The width (middle value of the three shown widths) of the groove 122 extending along the length of the wall panel 120 is shown for each example.

The wall panel 120 may be mounted to the base unit 110 by screws 700 or nails (see e.g., Figures 10-11 ), by driving them, preferably obliquely downwards, through the bottom of the wall panel 120 and into the base unit 110. This operation is primarily a temporary means until the wall panel 120 can be permanently fastened to the ceiling or flooring, e.g., by the aid of brackets 800 (see e.g., Figures 11 -12) and bolts 850 or screws.

The bottom of the wall panel 120 comprises an elongate cavity or groove 122 extending along the length of the wall panel 120 (see Figures 7A and 7B).

The wall panel’s bottom may be provided with a joint seal 124, such as one or more bands of polymeric foam seal, as depicted in Figure 7A, here shown with one band on each side of the elongate cavity or groove 122. Furthermore, the wall panel’s first and/or second ends may be provided with a joint seal 126, such as one or more bands of polymeric foam seal, as depicted in Figures 7A, 8A, and 8B. Finally, the wall panel’s top may be provided with a joint seal 128, such as one or more bands of polymeric foam seal, as depicted in Figure 8B.

Figures 15A and 15B are exemplary illustrations of how to connect wall panels according to the present invention.

References

100 Modular wall system

110 Base unit

112 Upper part

113 Space

114 Lower part

120 Wall panel

122 Cavity or groove

124 Joint seal

126 Joint seal

128 Joint seal

130 Mounting hole

135 Bolt

140 Leveling hole

145 Adjustment bolt

200 Timber frame section

300 Panel board section

400 Foundation

500 Wedge

600 Casting material

700 Screw

800 Bracket

850 Bolt