Background of the Invention

Field of the Invention

This invention relates to a frame structure, more particularly to a frame structure that is utilised in fabricating a wall panel or a building for reinforcing the wall panel.

Description of Related Arts

In a building and a wall panel construction, constructor always aims to build a wall with high strength to reinforce and enhance life span of the wall panel or building structure. There are several attempts in constructing a frame structure which is integrately use and have been disclosed in prior art. U.S. Patent 8,312,687 B2 disclosed a support frame system for placing and securing reinforcing bars, comprising a beam member having an elongated upper surface; a plurality of saddles disposed at a predetermined fixed spacing along opposite edges of the elongated upper surface, each saddle defining a V-shaped notch for receiving a reinforcing bar; a plurality of sockets disposed at a predetermined fixed spacing along the elongated upper surface proximal at least a portion of the saddles; and a clip designed to engage a respective pair of the sockets for securing a reinforcing bar in a respective one of the saddles.

U.S. Patent publication no. 2012/0047816 A1 disclosed a prefabricated wall panel includes molds for casting reinforced concrete (RC) elements. The prefabricated wall panel includes foam boards, foam glass panels fixed to the foam boards, fabric mesh fixed to the foam glass panels, wire mesh fixed to the fabric mesh, and an exterior wall finish fixed to the wire mesh. Spaces defined by the foam boards and the form glass panels forms the molds for casting RC columns and beams.

Another example is disclosed in U.S. Patent 6,508,447 B1 . A masonry wall is made from a plurality of masonry units and bounded by a frame. The apparatus can be used in conjunction with a vertical post-tensioning bar or vertical reinforcement bar to transfer forces perpendicular to the plane of wall to frame. The apparatus further includes a brace and a face. The brace can include at least one adjustment slots and attaching the brace to the frame. Flanges are extended outwardly from the face to define a bar receiving area.

The frame construction of the wall panels that disclosed in prior arts are complicated and required high time consumption. Therefore, there exists a need to provide an alternative frame structure for reinforcing a wall panel. Summary of Invention

It is an objective of the present invention to provide a frame structure integrated with an overlay to be used in a wall panel configuration to reinforce said wall panel.

It is also an objective of the present invention to provide a strong and easy to be prepared frame structure integrated with an overlay.

It is yet another objective of the present invention to provide a frame structure, which includes a top plate and a base plate having different configuration. It is a further objective of the present invention to provide a frame structure that able to optionally receive a reinforcement bar and an infill including a concrete aggregate in a single assembly.

Accordingly, these objectives may be achieved by following the teachings of the present invention. The present invention relates to a frame structure for a wall panel comprising of a metal frame integrated with an overlay, and characterized in that: said metal frame comprises a plurality of perforations and wherein said perforation has an elongated hexagonal shape; a base plate and a top plate, are each mounted to end of the metal frame for further reinforcing said frame structure; and the overlay coupled to two sides of the metal frame, forming a space therebetween for receiving an infill. Brief Description of the Drawings

The features of the invention will be more readily understood and appreciated from the following detailed description when read in conjunction with the accompanying drawings of the preferred embodiment of the present invention, in which:

Fig. 1 is a perspective view of an assembly of a frame structure integrated with an overlay.

Fig. 2 is a detailed view of a perforation of a metal frame.

Fig. 3 is a side view from view B of Fig. 1 without finishing surface.

Detailed Description of the Invention

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a basis for claims. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modification, equivalents and alternatives falling within the scope of the present invention as defined by the appended claims. As used throughout this application, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words "include," "including," and "includes" mean including, but not limited to. Further, the words "a" or "an" mean "at least one" and the word "plurality" means one or more, unless otherwise mentioned. Where the abbreviations or technical terms are used, these indicate the commonly accepted meanings as known in the technical field. For ease of reference, common reference numerals will be used throughout the figures when referring to the same or similar features common to the figures. The present invention will now be described with reference to Figs. 1 -3. The present invention relates to a frame structure for a wall panel comprising of a metal frame (1 1 ) with an overlay (12), and characterized in that: said metal frame (1 1 ) comprises a plurality of perforations (13) and wherein each of said plurality of perforations (13) comprises an elongated hexagonal shaped configuration, a base plate (14) is placed at one end of the metal frame (1 1 ) for supporting the metal frame (1 1 ); and a top plate (15) mounted to another end of the metal frame (1 1 ) for covering and supporting the metal frame (1 1 ); and the overlay (12) is placed over two sides of the metal frame (1 1 ), covering the metal frame (1 1 ). In a preferred embodiment of the present invention, the overlay (12) is a wire mesh, a concrete board or a combination thereof. Example of wire mesh used in the present invention includes a metal ribbed lath, an expanded metal, a cage or a combination thereof. Example of the concrete board used in the present invention includes a cement board. The overlay (12) is optionally being covered with a finishing surface including a concrete board including a cement board, a plaster or a combination thereof, to enhance the outer appearance of said frame structure.

In a preferred embodiment of the present invention, the base plate (14) is preferably having a L-shaped profile, a U-shaped profile or a combination thereof.

In a preferred embodiment of the present invention, the top plate (15) is preferably having a L-shaped profile, a U-shaped profile or a combination thereof.

Referring to Fig. 1 , a cross-sectional view of an assembly of the metal frame (1 1 ) integrated with the overlay (12) is illustrated. Said metal frame (1 1 ) has the plurality of perforations (13), which are spaced apart from each other along the metal frame (1 1 ). Said perforation (13) is preferably in the elongated hexagonal shape. As can be seen in Fig. 2, a detailed view of the perforation (13) is shown. Each of said perforation (13) includes six corners, for optionally receiving and supporting a reinforcement bar (16). The corners of the elongated hexagonal shaped perforation (13) form the grooves. The reinforcement bar (16) is preferably placed at two opposing grooves of the perforation (13) as shown in Fig. 3. For instance, the reinforcement bar (16) is placed on a top groove and bottom groove of the perforation (13). The reinforcement bar can be arranged in various ways within the six corners of the perforation (13) depending on the construction structure and the needs of a user. Any method can be utilised to secure the reinforcement bar (16) to the perforation and in the preferred embodiment of the present invention, it is done by tying the reinforcement bar (16) to the perforation (13) using a wire. In a preferred embodiment of the present invention, the metal frame (1 1 ) can be placed vertically or horizontally. In an example of placing the reinforcement frame (1 1 ) vertically, the base plate (14) is coupled to bottom end of the metal frame (1 1 ). The top plate (15) is preferably coupled to the upper end of the metal frame (1 1 ). In the preferred embodiment of the present invention, the top plate (15) and the base plate (14), are each configured in the U-shaped profile having a plurality of the elongated hexagonal shaped perforation. In another preferred embodiment, the top plate (15) and the base plate (14) can be a combination of two L-shaped profiles, a combination of one L-shaped profile (top plate (15)) and one U-shaped profile (base plate (14)) (as illustrated in Fig. 3), or a combination of two U-shaped profiles. The L-shaped profile can be in inverted L-shaped profile.

The overlay (12) is then placed over the two sides of the metal frame (1 1 ) covering the base plate (14) and top plate (15), preferably opposite sides of the metal frame (1 1 ), by a fastener such as a nail, a screw or a pneumatic nail. This forms the space between the overlays (12) on the two sides of the metal frame (1 1 ), wherein said space is optionally filled with an infill (18) including air or a concrete aggregate such as cement. The overlays (12) will partially cover the top plate (15) and the base plate (14) as shown in Fig. 3.

The finishing surface (17) is placed over the overlays (12) preferably over an exterior surface of the overlay (12). In examples, if the cement board is used as the overlay (12), the finishing surface (17) will be a skim-coat plaster. If the wire mesh is used as the overlay (12), the finishing surface (17) will be a cement-sand plaster.

The configuration of the frame structure is simple and easy. Besides that, said frame structure also has high strength and can be used in wall panel and building construction.

Although the present invention has been described with reference to specific embodiments, also shown in the appended figures, it will be apparent for those skilled in the art that many variations and modifications can be done within the scope of the invention as described in the specification and defined in the following claims.

Description of the reference numerals used in the accompanying drawings according to the present invention:

Reference

Description

Numerals

1 1 Metal frame

12 Overlay

13 Perforation of the metal frame

14 base plate

15 Top plate

16 Reinforcement bar

17 Finishing surface

18 Infill