HK1260263B - A pre-assembled wall panel, a multi-story building, a method to construct a utility wall of a building - Google Patents

Description

Preassembled wall panels, multi-story buildings, and methods of constructing utility walls

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 62/304,862, filed on March 7, 2016, which is hereby incorporated by reference in its entirety for any purpose.

Technical Field

The present invention relates to preassembled wall panels, multi-story buildings, and methods of constructing utility walls.

Background Art

The construction industry is increasingly using modular construction techniques to improve efficiency. In modular construction, entire structures or sub-assemblies of a structure are prefabricated at off-site facilities. The completed assemblies are then transported to the construction site for installation. While the structure of these components can be prefabricated, other components may need to be installed at the construction site. These components may include electrical wiring, plumbing, data cables, and final finishes. Some of these components may require skilled labor to install. Requiring labor to travel to multiple construction sites rather than a single prefabrication facility increases labor costs and reduces time efficiency.

Summary of the Invention

An exemplary preassembled wall panel may include a panel frame comprising a plurality of studs and a first end member and a second end member, the first end member being disposed at one end of the studs and the second end member being disposed at an opposite end of the studs, each of the plurality of studs being connected to the first end member and the second end member. The wall panel may also include a first wall panel attached to a first side of the panel frame, and a second wall panel attached to a second side of the panel frame opposite the first side. The wall panel may also include a plurality of spacers attached to at least one of the first wall panel and the second wall panel, each of the plurality of spacers being configured to support a finish panel in a spaced relationship from at least one of the first wall panel and the second wall panel. The wall panel may also include a tube disposed between the first wall panel and the second wall panel and extending between the opposite end members, wherein the tube includes a tube splitter, and wherein a free end of the tube splitter extends through an opening in the first wall panel or the second wall panel.

A multi-story building may include: a structural frame including at least one beam; and preassembled wall panels connected to the structural frame and including upper panel portions extending above a floor surface of an upper unit of the building and lower panel portions extending below a ceiling surface of a lower unit of the building.

A method for constructing a utility wall of a building may include: attaching a first preassembled wall panel to the structural frame of the building; vertically positioning a second preassembled wall panel above the first preassembled wall panel, wherein each of the first preassembled wall panel and the second preassembled wall panel includes a tube at least partially located inside the wall panel, the tube including a diverter exposed outside the wall panel; attaching the second preassembled wall panel to the structural frame of the building; and connecting a tube fitting to each of the diverters to fluidly connect the tubes of the first preassembled wall panel and the second preassembled wall panel.

The foregoing summary is illustrative only and is not limiting in any way. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent with reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features of the present disclosure will become more fully apparent from the following description and the appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the present disclosure and, therefore, are not to be considered limiting of its scope, the present disclosure will be described with additional specificity and detail through use of the accompanying drawings, in which:

FIG1A is an isometric view of a wall panel;

FIG1B is an exploded isometric view of a portion of the wall panel of FIG1A;

FIG2 is a partial cross-sectional view of the wall panel;

Figure 3 is a diagram of a multi-story building;

FIG4 is an isometric view of another wall panel;

FIG5A is an isometric elevation illustration of a portion of a building;

FIG5B is another isometric elevation illustration of a portion of a building;

FIG6 is a partial cross-sectional view of adjacent wall panels;

FIG7 is a cross-sectional view of a wall panel attached to other structures of a building;

FIG8 is a partial cross-sectional view of the finish panel system; and

FIG9 is a flow chart of an exemplary method;

These figures are arranged in accordance with at least some embodiments of the present disclosure.

DETAILED DESCRIPTION

The following detailed description refers to the accompanying drawings, which form a part of the detailed description. In the drawings, like numbers generally refer to like parts unless the context indicates otherwise. The exemplary embodiments described in the detailed description, drawings, and claims are not intended to be limiting. Other embodiments may be used, and other changes may be made, without departing from the spirit and scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure as generally described herein and shown in the drawings may be arranged, replaced, combined, separated, and designed in a wide variety of different configurations, all of which are implicitly referred to herein.

The present disclosure relates, in particular, to methods, systems, products, devices and/or apparatus generally relating to utility panels, which may include an outer panel, a plurality of studs coupled to the outer panel, a hat-shaped channel coupled to the plurality of studs opposite the outer panel, and an inner panel coupled to the hat-shaped channel opposite the plurality of studs, wherein the hat-shaped channel is perpendicular to the studs.

In some embodiments, a building can be installed with utilities such as pipes and/or electrical wiring. In some embodiments, components related to one or more utilities can be integrated into preassembled panels. For example, plumbing components such as pipes can be integrated into preassembled wall panels. In some embodiments, preassembled panels can be installed when a building is constructed. The preassembled panels can provide the outer walls of the building and the inner walls of the building. In some embodiments, one side of the preassembled panel can provide the inner wall and the opposite side can provide the outer wall. In some embodiments, both sides of the preassembled panel can provide the inner wall. In some embodiments, multiple preassembled panels can be connected together to form one or more complete walls of a building. In some embodiments, the preassembled panels can be load-bearing and can provide support for floors, roofs and/or other inner or outer walls. In some embodiments, the preassembled panels can be non-load-bearing. In some embodiments, the preassembled panels can be connected to the load-bearing structure (e.g., structural frame) of the building. For example, the load-bearing structure can be an external construction steel frame.

In some embodiments, one or more preassembled panels may have utilities preinstalled. Utilities may include electrical appliances, plumbing, heating and air conditioning, telecommunications, and/or other utilities. Preassembled panels with preinstalled utilities may be referred to as utility siding panels or simply siding panels. A siding panel may have one or more utilities preinstalled. Installing utilities during fabrication of the siding panels prior to delivery to the construction site may allow for faster assembly of the building and, in some embodiments, may reduce the number of skilled labor required to install utilities in the building.

In some embodiments, multiple wall panels can be coupled together. The wall panels can be coupled together horizontally and/or vertically. Utilities within the panels can also be connected together horizontally and/or vertically. This can allow utilities to be provided to multiple units on a single floor of a building, as well as multiple units on multiple floors.

In some embodiments, the wall panel may include two wall panels with a gap space between them. In some embodiments, the wall panels may be attached to opposite sides of a plurality of studs, allowing for the gap space between the wall panels to be serviced. The plurality of studs may be connected to opposing first and second end members to form a panel frame. The first end member may be disposed at one end of the stud, and the second end member may be disposed at an opposite end of the stud. Each of the plurality of studs may be connected to the first and second end members. The studs may be spaced apart from one another. Utilities may be installed within the gap space and between the studs. In some embodiments, the studs may be stamped, which may allow for the installation of utilities through openings in the studs. In some embodiments, the wall panel may include spacers attached to an outer surface of the wall panel, for example, for attaching a wall finish material. The wall finish material may include an interior or exterior finish such as an interior finish panel or exterior cladding. The spacers may provide the finish material in a spaced relationship relative to the wall panel, thereby defining a space between the finish material and the wall panel. This space may be used for utilities, for example for establishing connections between utility components of one board and those of another board.

In some embodiments, pipes for plumbing and/or other utilities may extend vertically within the siding. In some embodiments, the pipes may extend between studs. In some embodiments, the pipes may be surrounded by foam. In some embodiments, the foam may substantially fill the space between the studs and the siding. In some embodiments, the foam may at least partially support the pipes. In some embodiments, the foam may help maintain alignment of the pipes. In some embodiments, the siding may include insulating material such as mineral wool. In some embodiments, insulation may be provided between the studs.

In some embodiments, the material composition of the panel frame of the wall panel can be primarily metal such as steel. In some embodiments, the material composition of the panel frame of the wall panel can be primarily aluminum. In other embodiments, the wall panel components can be made of a variety of suitable building materials, ranging from metals and/or metal alloys to wood and wood polymer composites (WPC), wood-based products (lignin), other organic building materials (bamboo) to organic polymers (plastics), to hybrid materials, or earthen materials such as ceramics. In some embodiments, cement or other castable or moldable building materials can also be used. In other embodiments, any combination of suitable building materials can be combined by using one building material for some elements of the utility panel and other building materials for other elements of the utility panel. The selection of any material can be based on material selection (such as those provided in the International Building Code) or based on the knowledge of a person of ordinary skill in the art when determining the load-bearing requirements of the structure of the building. Larger and/or taller structures may have greater physical strength requirements than smaller and/or lower buildings. Adjusting the building materials to accommodate the structural size, loads, and environmental stresses can determine the best economic choice of building materials for all components of the utility panel described herein. The availability of various building materials in different parts of the world may also affect the selection of materials used to construct the systems described herein. The adoption of the International Building Code or similar codes may also affect the selection of materials.

Any reference to "metal" herein includes any construction-grade metal or metal alloy that may be suitable for use in the manufacture and/or construction of the utility panels and components described herein. Any reference to "wood" includes wood whether chemically treated, refined, processed or simply harvested from a plant, wood laminate products, wood pressed products, wood polymer composites (WPC), bamboo or bamboo-related products, lignin products, and any plant-derived products. Any reference to "concrete" herein includes any construction-grade curable composite material comprising cement, water, and granular aggregate. Granular aggregate may include sand, gravel, polymers, ash, and/or other minerals.

Turning now to the drawings. Figures 1A and 1B show illustrations of isometric and partially exploded views of an exemplary preassembled wall panel 316 arranged in accordance with at least some embodiments described herein. Figure 1A shows, among other things, the panel frame 320, studs 322, end members 324, respective first and second wall panels 330, 340, insulation 338, tube support members 370, and spacers 323 of the preassembled wall panel 316. Figure 1B primarily shows the panel frame 320, studs 322, end members 324, respective first and second wall panels 330, 340, interstitial spaces 326, insulation 338, spacers 323, cavities 327, and tube support members 370 of the preassembled wall panel 316. The various components shown in Figures 1A and 1B are merely embodiments, and other variations, including removing components, combining components, and substituting components, are contemplated.

The preassembled siding 316 may include a panel frame 320, which may include end members 324 and a plurality of studs 322. The end members 324 may be positioned at opposite ends of the studs 322 and connected thereto. In some embodiments, the studs 322 may be formed from a metal material such as aluminum or steel. In some embodiments, the studs 322 may be from approximately 8 inches deep to approximately 12 inches deep. In some embodiments, the studs 322 may be approximately 10 inches deep. When the siding 316 is installed in a building, the studs 322 may extend vertically. In some embodiments, the studs 322 may be regularly or irregularly spaced. In some embodiments, the studs 322 may be spaced two feet on center. The spacing of the studs may be adjusted based on the load requirements of the structure. In some embodiments, the studs may be implemented using wood studs. In some embodiments, any other suitable building material (e.g., fiber-reinforced composite materials) may be used. In some embodiments, openings may be present in the studs 322, which may allow for horizontal distribution of utilities. The studs 322 can define vertical gap spaces 326 for the vertical distribution of utilities between the studs 322, and the openings in the studs 322 can allow connection between utilities in adjacent vertical gap spaces 326. Insulators 328 can be provided in one or more gap spaces between the studs 322. The studs 322 can be connected to opposing end members 324, which together with the external studs can define the peripheral sides of the wall panels 316. During assembly, the wall panels 316 can be arranged side by side (e.g., vertically adjacent to or horizontally adjacent to another panel). In some embodiments, the peripheral sides of adjacent wall panels can abut each other. In some embodiments, an intermediate layer can be arranged between adjacent sides of the wall panels. In some embodiments, interface components or assemblies, such as for sealing the joints between adjacent panels, can be arranged between adjacent sides of the wall panels.

The first wall panel 330 and the second wall panel 340 can be connected to opposite sides of the panel frame 320. For example, the wall panels can be fastened (e.g., using threaded fasteners) to opposite sides of the studs 322 and to the opposing end members 324. The first and/or second wall panels can be constructed from one or more prefabricated panels 332, 342 of non-combustible material. As will be understood by one of ordinary skill in the art, a non-combustible material can be a material that does not readily ignite, burn, support combustion, or release flammable vapors when exposed to fire or heat. Examples of non-combustible materials include inorganic mineral materials such as cement, gypsum, and magnesium oxide, which are commonly used in interior and exterior sheathing products. Other embodiments may include glass, fiberglass, or glass/fiberglass cladding, which can be used in combination with the inorganic mineral product to, for example, reinforce a core formed from the inorganic mineral product or a lining side of the core. In other embodiments, the wall panels or components thereof can be made from a variety of other suitable building materials.

In some embodiments, a first wall panel 330 can be disposed on a first side 331, which can serve as an interior wall of a building. A second wall panel 340 can be disposed on a second, opposite side 341, which can serve as an exterior wall of the building. Wall panel 316 can be configured to support a finish material on one or both of first and second sides 331, 341. In some embodiments, a spacer 323 can be attached to either or both of first and second wall panels 330, 340. Spacer 323 can be configured to support a finish panel, which can be an interior finish panel or an exterior finish panel. Spacer 323 can be configured to attach the finish panel in a spaced relationship relative to the wall panel. The finish panel can be an interior finish panel, such as a wood panel, laminate, tile panel, metal panel, plastic panel, composite panel, or other type of panel. The finish panel can be attached to the spacer, for example, by mechanically fastening it to the spacer. In some embodiments, the finish panel can be bonded (e.g., permanently or removably attached). In some embodiments, the finish panel can be removably attached, for example, in a manner such that removal of the finish panel does not cause substantial damage to the siding and/or finish panel. In some embodiments, the finish panel can be an exterior finish panel such as exterior cladding that can be provided on an exterior wall.

In some embodiments, the spacer 323 can be implemented in the form of a first slender member 325 that can extend continuously along the length of the wall panel 316. The spacer 323 can have a length I. In some embodiments, the spacer 323 can extend the entire length of the panel 316 or a portion of the length of the panel 316. The spacer 323 can have a height h, which can define the spacing distance d between the wall panel (e.g., the first wall panel 330) and the end trim panel when the end trim panel is attached thereto. The height and length of the spacers of the wall panel can be modified to suit a particular application. The spacers can be set on one or both sides of the wall panel. For example, the spacers can be set on the inside, for example, so that one or more end trim panels are attached thereto. In some embodiments, the spacers (e.g., a hat channel or a sub-keel) can be set on the outside of the wall panel, for example, so that one or more external end trim panels are attached thereto. In some embodiments, the spacers on the outside of the wall panel can be attached on site. In some embodiments, the spacers on the outside of the wall panels may be attached at the factory and may form part of a pre-assembled wall panel.

A plurality of spacers 323 (e.g., first elongated members 325) may be positioned along the outer surface of the wall panel. The spacers (e.g., first elongated members 325) may be substantially parallel to one another (e.g., plus or minus 15 degrees). When the wall panel 316 is installed, the spacers 323 (e.g., first elongated members 325) may extend substantially horizontally. The spacers 323 (e.g., first elongated members 325) may be spaced apart to define a horizontally extending cavity 327 therebetween. The horizontally extending cavity 327 may accommodate utility components behind the finish panel. In some embodiments, the spacers 323 may be implemented using a plurality of shorter brackets that may be arranged in a row along the outer surface of the wall panel. In some embodiments, the spacers 323 may include one or more hat-shaped channels 325-3. The hat-shaped channels 325-3 may be arranged perpendicularly (e.g., plus or minus 15 degrees) to the studs 322 on opposite sides of the wall panel (e.g., first wall panel 330). In some embodiments, the spacer 323 may include one or more C-shaped or J-shaped channels 325-1, 325-2. In other embodiments, the spacer may include brackets having different cross-sectional shapes. The wall panels and/or components thereof may be attached to other structures or components using various techniques, such as by mechanical fastening (e.g., using rivets, threaded fasteners (e.g., screws, bolts, nut and bolt combinations, etc.), or other types of mechanical fasteners). In some embodiments, the components may be bonded (e.g., adhered or glued) to other components. Various techniques for connecting components may be used without departing from the scope of this disclosure.

The wall panel 316 may include a lower panel portion 316-1 and an upper panel portion 316-2. When the wall panel 316 is installed, the lower panel portion 316-1 may span the height of at least a portion of the lower floor of the building. The upper panel portion 316-2 may span the height of at least a portion of the upper floor of the building, and in some embodiments, may span more than one floor of the building. At least some of the spacers 323 may be spaced farther apart than other spacers. In some embodiments, at least some of the spacers may be spaced far enough apart to define a cavity 327-3, which is configured to accommodate other structures such as floors or horizontal members (e.g., beams) of the structural frame of the building. The cavity 327-3 may be located at the floor-delimiting portion 316-3 of the wall panel 316. The floor-delimiting portion 316-3 may be located between the lower portion 316-1 and the upper portion 316-2 of the wall panel. In some embodiments, the wall panel 316 may include multiple floor-delimiting portions, each of which may be configured to be connected to other structures. In some embodiments, a bracket 329 can be attached to the floor delineating portion 316-3. The bracket 329 can be used to align and/or connect the wall panel 316 to another structure (e.g., a beam or floor as shown in FIG7). The bracket 329 can have an L-shaped cross-section. The bracket 329 can be implemented in the form of an angle bracket such as an angle iron. The bracket 329 can have different shapes or be formed from materials other than metal.

The wall panel 316 may include a reinforcement member 380 located within the wall panel 316. When the wall panel 316 is installed in the building, the reinforcement member 380 can be arranged horizontally and can therefore be interchangeably referred to as a horizontal reinforcement member. The reinforcement member can be implemented in the form of a plate, such as a metal plate (e.g., a steel plate). The reinforcement member 380 can be adjacent to the cavity 327-3. The reinforcement member 380 can be arranged between the first wall panel 330 and the second wall panel 340, located on the side of the wall panel opposite the cavity 327-3. The reinforcement member 380 can abut each wall panel. The reinforcement member 380 can be located in the floor-demarcating portion 316-3 of the wall panel 316 and can be used to reinforce the wall panel in the thickness direction, particularly at locations where the panel may abut other structures such as beams or floors. Insulation 382 can be arranged below or above the reinforcement member 380. The insulation 382 can include mineral wool and can be arranged perpendicular (e.g., plus or minus 15 degrees) to the wall panel.

In some embodiments, a tube (see, for example, tube 350 in FIG. 2 ) may be arranged between the wall panels of the wall panel. When the wall panel is installed, the tube may extend vertically between the studs 322. For clarity of illustration, the tube is omitted from the exploded view in FIG. 1B to avoid cluttering the illustration. It should be understood that, according to the present disclosure, the wall panel 316 or any other embodiment of the wall panel may include one or more tubes. In some embodiments, the wall panel 316 may include multiple tubes such as water pipes (e.g., hot and cold water supply lines) and drain pipes. The tubes may extend between opposing end members 324. The tubes may include at least one tube splitter, and in some embodiments, multiple tube splitters. The tube splitters may be configured to separate the flow paths of the tubes. In some embodiments, the tube splitters may be configured to redirect at least a portion of the fluid in the tubes. In some embodiments, and depending on the type of tube (e.g., water supply pipe or drain pipe), the tube splitters may be configured to direct another flow path into the tubes. A pipe splitter can include any structure operable to combine two or more flow paths into fewer flow paths, or a structure operable to divide a flow path into multiple flow paths. In some embodiments, the pipe splitter can include a pipe fitting that is connected to or integrally formed with a section of pipe. In some embodiments, the pipe splitter can include a T-shaped element (e.g., a T-shaped pipe section). In some embodiments, the pipe splitter can include a Y-shaped element (e.g., a Y-shaped pipe section).

The free end of the tube diverter can extend through the wall panel. For example, the free end of the tube diverter can extend through an opening in one of the wall panels, with the free end exposed to the exterior of the wall panel so that it can be connected to other piping components. The tube diverter can include a pipe fitting such as a T-fitting or a Y-fitting. In some embodiments, the tube diverter can be connected to a separate pipe segment that forms the pipe, or can be formed integrally with the pipe segment. In some embodiments, the ends of the pipe can be covered and enclosed within the panel frame. As will be further described below, the tube diverter can be used to form a fluid connection between the pipes of vertically adjacent panels.

The wall panel 316 may also include a tube support member 370. The tube support member 370 may be connected to the panel frame 320 and operably engage a tube (e.g., tube 350 in FIG. 2 ). Thus, the tube support member 370 may connect the tube to the structure of the wall panel 316 to reduce movement of the tube, for example, during transportation and installation of the wall panel 316. The tube support member 370 may be arranged transverse to the stud 322. In some embodiments, the tube support member 370 may extend substantially perpendicular (e.g., plus or minus 15 degrees) to the stud. In some embodiments, multiple tube support members 370 may be included. The tube support member may include a tube bracket 372. The tube bracket 372 may be attached to a cross member 374. The cross member 374 may be implemented using a C-channel (e.g., a metal C-channel), and the tube bracket 372 may be operably coupled to the C-channel. In some embodiments, the cross member 374 may be implemented using a UNISTRUT channel from Atkore International Ltd. The tube bracket may be implemented using a conduit clamp configured for use with a UNISTRUT channel. In some embodiments, different cross members and pipe supports can be used. In some embodiments, multiple cross members 374 can be attached (e.g., fastened or welded) to track 376, and the track can be used to connect multiple cross members 374 to one or more studs 322. In some embodiments, track 376 can extend laterally through multiple gap spaces 326 to connect to multiple studs 322. Track 376 can extend the entire distance between the outer studs. In some embodiments, the base of track 376 can directly abut the studs, and cross member 374 can be received in the gap space 326 between two adjacent studs 322. Wall panel 316 may include multiple pipe support members for supporting multiple pipes. Pipe supports of different sizes can be used to attach pipes of different diameters to the panel frame.

FIG2 is a partial cross-sectional view of a wall panel 316 according to another embodiment of the present disclosure. FIG2 illustrates an exemplary wall panel (e.g., wall panel 316) after installation in a building and shows a finish panel attached to the wall panel. FIG2 shows a portion of the wall panel 316, showing a panel frame 320, a gap space 328, an insulator 328, a first wall panel 330 and a second wall panel 340 disposed on sides 331 and 341, respectively, a spacer 323 including a first elongated member 325 and a second elongated member 335, a cavity 327, a height h of the spacer and a spacing distance d associated with the cavity 327, a finish panel 345 including an inner finish panel 346 and an outer finish panel 347, a tube 350, a tube support member 370, a cross member 374, a tube bracket 372, and a track 376. The various components shown in FIG2 are merely exemplary embodiments, and other variations, including removing components, combining components, and replacing components, are contemplated.

As shown, after the wall panel 316 is installed, a finish panel 345 can be attached to one or both sides of the wall panel. The wall panel 316 can include a spacer 323 attached to one or both of the first wall panel 330 and the second wall panel 340. The spacer can be implemented using a slender member having a closed (e.g., box-shaped) or open (e.g., hat-shaped channel, C-shaped channel, J-shaped channel, or other) cross-section. The height of the spacer can define the dimension d of the cavity 337. In some embodiments, spacers with different heights can be used on each side of the wall panel. For example, the height of the first elongated member 325 on the side 331 of the wall panel 316 can be greater than the height of the second elongated member 335 on the side 341 of the wall panel 316. The side 331 can provide an inner wall and the inner finish panel 346 can be attached to the first elongated member 325. The side 341 can provide an outer wall and the outer cladding 347 can be attached to the second elongated member 335. In such an embodiment, additional layers may be provided between the wall panel 340 and the spacer 323 on the side 341. For example, a weather barrier may be provided (e.g., bonded) to an outer surface of the wall panel 340, and the second elongated member 335 may be disposed over the weather barrier.

FIG3 illustrates an exemplary multi-story building 102 arranged in accordance with at least some embodiments described herein. FIG3 shows the building 102, stories 103, structural frames 104, columns 106, beams 108, cross braces 110, cells 112, floor-ceiling panels 114, and wall panels 116. The various components shown in FIG3 are illustrative only, and other variations, including the removal, combination, and substitution of components, are contemplated.

The building 102 may include two or more floors or levels 103. The building 102 may be classified as a low-rise building, a mid-rise building, or a high-rise building based on the number of floors (each city or zoning authority may define building height in any manner they deem appropriate). The building 102 may include one or more siding panels 116 that may define the walls of one or more units 112 of the building 102. In some embodiments, the one or more siding panels 116 may be non-load-bearing and may be arranged adjacent to one or more elements of the building's structural frame 104. The siding panels as described herein may be applicable to buildings with any number of floors (levels), including mid-rise buildings as well as high-rise buildings. In some embodiments, the building may be a multi-dwelling residential building having eight or more floors. In some embodiments, the building may have fifteen or more floors, or in some embodiments, thirty or more floors.

Building 102 may include a structural frame 104. Structural frame 104 may include a plurality of columns 106, beams 108, and cross braces 110. Columns 106 may be oriented vertically, beams 108 may be oriented horizontally, and cross braces 110 may be oriented obliquely relative to columns 106 and beams 108. Beams 108 may extend between and be attached to adjacent columns 106 to connect adjacent columns 106 to one another. Cross braces 110 may extend between and be attached to connected beams 108 and columns 106 to provide additional rigidity to structural frame 104. In some embodiments, one or more walls of building 102 may not be load-bearing walls. In some embodiments, load-bearing support may be provided by structural frame 104. Columns, beams, and cross braces may be arranged to provide most or substantially all of the structural support for building 102. The frame may be used to provide decorative elements or to add structural support.

Building 102 may include a plurality of units or modules 112 operably arranged relative to a structural frame 104. Units 112 may be commercial, residential (e.g., apartment units), or both. Units 112 may be assembled at the construction site using a plurality of preassembled or prefabricated components (e.g., preassembled siding, flooring, and/or other components). Prefabricated components may be assembled independently of one another away from the construction site and transported to the construction site for installation. Components may be attached to the structural frame 104, adjacent components, or both at the construction site to form individual units 112. In some embodiments, building 102 may include an internal support structure. In some embodiments, prefabricated components may be attached to the internal support structure. In some embodiments, the use of prefabricated components as described herein can significantly reduce on-site time for constructing structures such as building 102. Each floor or level 103 of building 102 may include one or more units 112 defined by prefabricated components. These units may be standardized and repetitive, or unique and personalized. Mixed units of standard sizes and shapes may be combined with unique units on the same floor, or independently arranged on separate floors. In some embodiments, a unit may contain more than one floor.

These components may include one or more preassembled floor-ceiling panels 114 and one or more preassembled wall panels 116. The floor-ceiling panels 114 may be horizontally oriented and may define the floor of the upper unit and the ceiling of the lower unit. The individual floor-ceiling panels 114 may be arranged adjacent to each other in the horizontal direction and attached to each other, to one or more columns 106, to one or more beams 108, or to any combination thereof. In some embodiments, the floor-ceiling panels may be attached to the columns 106, beams 108, or to a combination thereof only around the perimeter of the panels. The wall panels 116 may be vertically oriented and may provide interior (e.g., unit division) and exterior (e.g., enclosure) walls of the building. The interior (e.g., unit division) walls may divide each floor into multiple units, a single unit into multiple rooms, or a combination thereof. The wall panels 116 may be attached to the floor-ceiling panels 114 with fasteners and then caulked, sealed, or both. In some embodiments, the wall panels 116 are disposed adjacent to horizontal structural members (e.g., beams 108) and/or vertical structural members (e.g., columns 106) of the structural frame 104. In some embodiments, the wall panels 116 may be substantially aligned or may be offset, but are generally parallel to the horizontal and/or vertical structural members.

Wall panel 316 can be used to implement wall panel 116 in a building such as building 102. For example, wall panel 316 can be used to construct a utility wall in a building such as building 102. In traditional construction, walls are typically constructed between the floor and ceiling of any given floor. In some embodiments, a preassembled wall panel (e.g., wall panel 316) can be configured to at least partially span multiple floors of a building. For example, a preassembled wall panel according to the present disclosure can span at least a portion of a lower floor and at least a portion of an upper floor. The preassembled wall panel may include an upper panel portion extending above the floor surface of an upper unit of the building and a lower panel portion extending below the ceiling surface of a lower unit of the building. In some embodiments, the upper panel portion can span the entire height of the upper floor and a portion of the height of another floor above the upper floor. That is, the preassembled wall panel can span an entire floor and a portion of the floor below and a portion of the floor above the floor it fully spans. The vertical length of the panel (e.g., the height of the panel) when installed can be from about 18 feet to about 22 feet. Preassembled wall panels according to some embodiments of the present disclosure can be up to about 21 feet tall, and in some embodiments, more than 21 feet tall. Preassembled wall panels according to some embodiments of the present disclosure can be configured to provide utilities, such as plumbing, to multiple units (e.g., the unit that the wall panel spans). In some embodiments, the wall panel can provide utilities to other units, such as units below and/or above the unit that the wall panel spans. That is, the wall panel can be configured to attach to vertically adjacent wall panels so that their utility components can be operably connected.

In some embodiments, the wall panel may include an inlet/outlet feature, such as to accommodate one or more doors or windows. FIG4 illustrates a preassembled wall panel 316' according to some embodiments. FIG4 illustrates the wall panel 316', first and second wall panels 330, 340, panel frame 320, spacer 323, cavity 327, opening 328, and lower and upper panel portions 316'-1, 316'-2, respectively. The various components shown in FIG4 are illustrative only, and other variations, including removing components, combining components, and replacing components, are contemplated.

The wall panel 316' can be similar to the wall panel 316 and include one or more components of the wall panel 316, all of which will not be repeated for the sake of brevity. For example, the wall panel 316' can include a panel frame 320, and a first wall panel 330 and a second wall panel 340, respectively. The panel frame 320 and the first wall panel 330 and the second wall panel 340 can be implemented using any of the embodiments herein. In the illustrated embodiment, the wall panel 316' can be configured to accommodate a door (not shown). To this end, the wall panel 316' can include an opening 338 that can be sized to receive a door (not shown). The wall panel 316' can include a lower portion 316'-1 that can span at least a portion of a lower unit when the wall panel 316' is installed. The wall panel 316' can include an upper portion 316'-2 that can span at least a portion of an upper unit when the wall panel 316' is installed. In some embodiments, the upper portion 316 ′- 2 may completely span (eg, extend the entire height of) an upper unit and may further span at least a portion of another unit above the upper unit.

Panel 316' can include spacers 323 that can support the finish panel in a spaced relationship from a wall panel (e.g., first wall panel 330). Spacers 323 can be arranged horizontally (e.g., plus or minus 15 degrees). Spacers 323 can be regularly or irregularly spaced from one another to define horizontally extending cavities 327. When wall panel 316' is installed in a building, one or more cavities 327 can be configured to accommodate other structures (e.g., beams or floor panels) therein.

Figures 5A and 5B illustrate isometric elevations of a portion of a building, such as building 102, for example, building 102. Figures 5A and 5B illustrate utility wall panels 316, 316', and 316", portions of wall panels 116-1, 116-2, and 116-3, portions of floor panels 114-1 and 114-2, pipe 350, drain pipes 350a and 350c, and water pipe 350b, and exemplary plumbing fixtures (e.g., sink 356 and toilet 358). The various components shown in Figures 5A and 5B are merely embodiments, and other variations, including the removal of components, combinations of components, and substitutions of components, are contemplated.

Wall panels 116-1, 116-2, and 116-3 are associated with three vertically adjacent floors 112-1, 112-2, and 112-3. Floors 114-1 and 114-2 provide floors and ceilings between vertically adjacent floors. Utility wall panels 316, 316', and 316" each span more than one floor. One or more of the utility wall panels 316, 316', and 316" can be configured to provide utilities to more than one floor. For example, wall panel 316 can include a plurality of pipes 350 that can run most of the length between the top and bottom sides of the wall panel to carry utilities to each of floors 112-1, 112-2, and 112-3. Wall panel 316 can include a drain pipe (e.g., pipe 350a) and a water pipe (e.g., pipe 350b). One or more of the pipes can have one or more pipe diverters. For example, drain pipe 350a may include a first pipe splitter 352a-1, a second pipe splitter 325a-2, and a third pipe splitter 352a-3. First pipe splitter 352a-1 and second pipe splitter 325a-2 may be used to connect pipe 350a to an adjacent wall panel below or above wall panel 316. Third pipe splitter 352a-3 (which may be one of a plurality of intermediate pipe splitters) may be used to route utility wiring within the unit. For example, third pipe splitter 352a-3 may be used to connect the drain pipe of a plumbing fixture (e.g., a skin, toilet, shower, or bathtub liner).

Similarly, water delivery pipe 350b may include one or more pipe splitters (e.g., pipe splitters 352b-1, 252b-2, 352b-3). Two of the pipe splitters (352b-1, 352b-2) can be used to connect pipe 350b to corresponding pipes in adjacent wall panels (e.g., hot water to the hot water supply line and cold water to the cold water supply line). The other pipe splitters of pipe 350b can be used to connect plumbing fixtures (e.g., faucets, shower heads, etc.). In some embodiments, the pipe splitters may have openings oriented toward the interior of the unit, such as pipe splitters 352a-1 and 352a-3 of pipe 550a in the embodiment of Figure 5A. In some embodiments, the pipe splitters may have openings oriented toward the interior of the unit, such as pipe splitters 352c-1 and 352c-3 of pipe 550c in the embodiment of Figure 5A. Tube splitters configured to connect to internal plumbing fixtures (e.g., tube splitters 352a-3 and 352c-3) can face inward (e.g., have openings oriented toward the interior of the unit). Tube 350 can include other tube splitters that can connect one tube within a panel to another tube within the panel. These tube splitters may not be exposed but may be substantially enclosed within the wall panel.

Connections between vertically adjacent wall panels can be made using pipe fittings (e.g., elbows and tees). One or more pipe fittings and/or one or more pipe segments can be connected to the free ends of pipe manifolds of corresponding pipes in adjacent wall panels. The free ends of the pipe manifolds can be easily accessible because they can be exposed (e.g., through an opening in the panel's wall sheathing). Firestops can be placed at the openings to meet fire safety requirements. Once the pipe connections are made, the connections can be concealed behind a finish panel.

FIG6 shows a partial cross-sectional view of adjacent wall panels. FIG6 shows a portion of wall panels 316-1 and 316-2, pipes 350-1 and 350-2, pipe splitters 352-1 and 352-2, and pipe fitting 354 between spacers 323-1 and 323-2. The various components shown in FIG6 are merely embodiments, and other variations, including the removal of components, combination of components, and substitution of components, are contemplated.

Wall panel 316-2 can be positioned vertically on wall panel 316-1, and the wall panels can be connected to each other and/or to other structures of the building. In some embodiments, the upper side of wall panel 316-1 can contact the lower side of panel 316-2. In some embodiments, end members 324-1 and 324-2 can be arranged opposite each other. In some embodiments, a tongue and groove interface can be provided between adjacent sides to strengthen the joint between the panels. Wall panel 316-1 can include a tube 350-1, and wall panel 316-2 can include a corresponding tube 350-2. Each end of the tube can be capped. The tubes can include one or more pipe splitters, such as pipe splitter 352-1 for pipe 350-1 and pipe splitter 352-2 for pipe 350-2. A pipe fitting 354 can be connected to each free end of pipe splitters 352-1 and 352-2. The pipe fitting can include a continuous pipe segment connecting two pipe splitters, or multiple pipe segments connected together between the free ends of the pipe splitters. The pipe splitters and pipe fittings can be configured so that the pipe connections are completely enclosed within the space behind the finish panel (e.g., within the cavity defined between the spacer 323-1 of the lower panel 316-1 and the spacer 323-2 of the upper panel 316-2). The pipe connections can extend vertically, horizontally, or at an angle. In some embodiments, cutouts can be provided through the spacer 323 to accommodate pipe connections between adjacent wall panels. For example, as previously described with reference to Figures 5A and 5B, pipe connections can be formed on either side of the wall panel.

FIG7 is a cross-sectional view of a wall panel attached to other structures of a building. FIG7 shows beam 108, floor 114, wall panel 316, bracket 329, first and second wall panels 330, 340, side panels 331, 341, finish panel 345, and spacers 323-1, 323-2. The various components shown in FIG7 are merely embodiments, and other variations, including the removal, combination, and replacement of components, are contemplated.

Wall panels 316, which may include first and second wall panels 330 and 340 defining opposing sides 331 and 341, can be attached to the building's structural frame (e.g., beams 108) and/or floor panels 114. Side 331 may be an interior side defining an interior wall of a unit. Side 341 may be an exterior side defining an exterior wall of the building. Wall panels 316 may span multiple floors of a building. Thus, wall panels 316 may be installed in the building after one or more floor panels are installed. Floor panels 114 may be attached (e.g., mechanically fastened) to beams 108. Wall panels 316 may be positioned on opposing sides of beams 108 using brackets 329 to connect (e.g., mechanically fasten) them to opposing sides of beams 108. In some embodiments, the panels may alternatively be welded to the frame. Gaps may be sealed and/or caulked, and finishes may be installed, for example, by attaching a finish panel 345 associated with each unit to spacers 323-1, 323-2 located within the corresponding unit.

Figure 8 is a partial cross-sectional view of a finish system according to other embodiments of the present disclosure. Figure 8 shows a wall panel 350 and a spacer 323 attached thereto, cavities 327 on opposite sides of the spacer 323, and adjacent upper and lower portions of finish panels 800a and 800b.

Each finish panel can include an inner layer and an outer layer and a pair of clamps arranged along opposite edge portions of the finish panel. Each finish panel can be approximately 4 feet wide and approximately 10 feet long. Other sizes can be used, such as widths of approximately 3 feet, 4 feet, 5 feet, or longer, and lengths of approximately 8 feet, 9 feet, 10 feet, or longer. It should be understood that the finish panels can be manufactured in any size as needed or suitable for a particular application. The inner layer (e.g., 802a, 802b) can be formed of a non-combustible material such as cement board or magnesium oxide board. The outer layer (e.g., 804a, 804b) can be a decorative layer. In some embodiments, the outer layer (e.g., 804a, 804b) can be in the form of ceramic, porcelain, or natural stone tiles. The pair of clamps can include a lower clamp 810 and an upper clamp 830. In the illustrated embodiment, the lower clamp 810 and the upper clamp 830 are shown attached to the lower portion of the finish panel 800b and the upper portion of the finish panel 800a, respectively. Although not shown in this view, it will be appreciated that the opposite (lower) end of finish panel 800a can be provided with a lower clamp 810, and the opposite (upper) end of finish panel 800b can be provided with an upper clamp 830. In this manner, multiple finish panels can be arranged side by side to cover any selected surface area.

Lower clamp 810 may have a generally Z-shaped cross-section defined by an outer flange 816, an inner flange 814, and an inclined wall 812. Outer flange 816 may include a lower flange portion 816-1 extending from the inclined wall in one direction and an upper flange portion 816-2 extending from the inclined wall 812 in an opposite direction. Upper flange 816-1, inclined wall 812, and inner flange 814 may define a channel 815 that receives the lower end of an inner layer (e.g., inner layer 802b of finish panel 800b). Upper clamp 830 may include corresponding inner and outer flanges 838, 836, and inclined wall 832 that define an inverted channel 835 that receives the upper end of an inner layer (e.g., inner layer 802a of finish panel 800a). Walls 812 and 832 may be inclined in opposite directions relative to inner flanges 814 and 838 of clamps 810 and 830, respectively. That is, the inclined wall 812 can be inclined toward the inner flange 814 (e.g., forming an acute angle with the inner flange 814), while the inclined wall 832 can be inclined away from the inner flange 838 (e.g., forming an obtuse angle with the inner flange 838). The inclined walls 812 and 832 can have matching slopes so that when the clamps 810 and 830 are nested together, the inclined walls 812 and 832 abut each other. The outer flange 836 of the upper clamp 830 can include a crosspiece 834. The crosspiece 834 can extend substantially perpendicular to the flange 836. The crosspiece 834 can be wide enough to seat the outer flange 816 of the clamp 810 and/or the outer layer 804b of the upper panel 800b. When the finish panel is installed, the edge 819 of the flange 816 and the bottom side of the outer layer can abut the crosspiece 834.

When installed, the end trim panels 800a, 800b can be attached to the wall structure (e.g., to the preassembled wall panels 316) with the inner layer closer to the wall structure than the outer layer. A typical installation may include first installing the lower end trim panel (e.g., end trim panel 800a), then the upper end trim panel (e.g., end trim panel 800b), followed by another end trim panel located vertically above the upper end trim panel, and so on. The lower panel can be installed, for example, by mechanically fastening the end trim panel to the spacer. Countersunk holes and fasteners can be used to allow the outer flange 816 of the lower clamp 810 to be placed substantially flush with the outer flange 836 of the upper clamp 830.

When installed, the angled wall 832 of the clamp 830 can be tilted downward toward the wall structure, and the clamp 810 can be slidably positioned in the clamp 810 by moving the upper trim panel vertically toward the installed lower trim panel. With the help of the weight of the end trim panel 800b, the angled wall 832 can operably engage the angled wall 812 to resist the outward horizontal movement of the end trim panel 800b. In this way, the upper end trim panel 800b can remain attached to the lower end trim panel 800a without the need for additional fasteners. In some embodiments, the upper portion of the upper end trim panel can be mechanically fastened before the next panel is attached thereto.

Finish panel attachment system 801 can be used to finish walls that might otherwise require sealing against moisture, such as bathroom surfaces. Typically, bathroom wall finish installation is very time-consuming, in part because each tile is laid one at a time, requiring significant time to level each tile and ensure equal spacing between tiles to achieve uniform grout lines. Furthermore, the layer beneath the tiles may require sealing to prevent moisture intrusion, and a foundation must be installed once all tiles are aligned in the desired pattern. Finish panel attachment system 801 can eliminate the need for grouting, sealing against moisture, and/or individual leveling and alignment of tiles. Each finish panel 800a, 800b arrives at the job site ready for attachment to the wall system, and installation can involve simply stacking one finish panel on top of another to form a continuous, impermeable wall covering. The clamp system not only simplifies finish panel installation but also eliminates the need for grouting between tiles, as the spaces between them can be filled with a portion of the clamp system (e.g., rungs 834). In some embodiments, an impermeable layer (e.g., waterproofing, which may be a membrane or applied as a liquid) may be applied over the flanges 816, 836 and/or between the inner layer 802, outer layer 804 of each finish panel to further reduce the risk of water seepage behind the finish panel.

FIG9 is a flow chart of an exemplary method. Method 900 can be used to construct a wall system for a building such as building 102. The exemplary method may include one or more operations, functions, or actions, as shown in one or more of blocks 905 to 925. The various blocks shown in FIG9 are illustrative only, and other variations, including removal, combination, and replacement of blocks, are contemplated. In some embodiments, the blocks may be executed in a different order. In some other embodiments, various blocks may be removed. In other embodiments, various blocks may be divided into additional blocks, supplemented with other blocks, or combined into fewer blocks. Other variations of these specific blocks are contemplated, including changes in the order of the blocks, changes in the contents of the blocks that are divided or combined into other blocks, and the like. In some embodiments, optional blocks may be omitted.

As shown in block 905, exemplary method 900 may include attaching a first preassembled wall panel to the structural frame of a building. The wall panel may be attached directly to the structural frame, such as by utilizing components that secure the panel to the frame, or the panel may be attached indirectly to the structural frame, such as by attaching the panel to other components (e.g., to a floor). The structural frame may include one or more beams and columns that are operably connected to provide structural support for a building, such as building 102. The first preassembled wall panel may be positioned adjacent to at least one beam. In some embodiments, the preassembled wall panel may at least partially span multiple floors and, in such embodiments, may be positioned adjacent to multiple vertically spaced beams. In some embodiments, attaching the first preassembled wall panel to the structural frame may include mechanically coupling angle brackets attached to the first preassembled wall panel to horizontal structural members (e.g., beams 108) of a building, such as building 102.

As shown in block 910, method 900 may further include positioning a second preassembled wall panel vertically above the first preassembled wall panel. Each of the first and second preassembled wall panels may include at least one tube at least partially located within the panel and including at least one tube splitter exposed to the exterior of the panel. The second preassembled wall panel may be positioned directly on the first preassembled wall panel such that the bottom side of the second preassembled wall panel contacts the top side of the first preassembled wall panel. Adjacent sides of the panels may be in direct contact with each other. In some embodiments, an intermediate layer may be positioned between adjacent sides of the panels. In some embodiments, an interface member may be provided between the panels to substantially seal the interface between the two panels. Method 900 may include attaching the second preassembled wall panel to the structural frame of the building, as shown in block 915. For example, the second panel may be directly attached to the structural frame, such as by coupling the panel to a structural member such as a beam. In some embodiments, the second panel may be indirectly attached to the structural frame, such as by attaching the panel to another panel (e.g., another panel and/or a floor).

Method 900 may also include connecting a pipe fitting to each of the flow dividers of the first and second wall panels to fluidly couple the pipes of the first and second preassembled wall panels. It should be understood that each wall panel may include multiple pipes, such as water supply pipes and drain pipes. The individual pipes may be fluidly connected using appropriately sized pipe fittings (e.g., including elbows, angles, tees, or other pipe segments). The hot and cold water lines of vertically adjacent panels may be fluidly connected so that water can be supplied to the units associated with a particular wall panel located above these lines. Similarly, the drain pipes may be connected so that wastewater can be discharged downwardly from any unit in the building to the main sewage line. In some embodiments, as shown in block 925, the pipes in the wall panel may include multiple pipe dividers, some of which may be used to connect pipes of adjacent panels, while others may be used to connect sanitary fixtures thereto. As previously described, wall panels according to the present disclosure may be sized to span multiple floors. That is, the wall panel may include an upper panel portion extending above the floor surface of the upper units of the building and a lower panel portion extending below the ceiling surface of the lower units of the building. In such an embodiment, the method may further include attaching a floor panel to the structural frame at a location between the upper panel portion and the lower panel portion. In some embodiments, the floor panel may be attached to the structural frame before any wall panels are attached to the structural frame. In some embodiments, the wall panels and floor panel may be located on opposite sides of the beam. The wall panels and floor panel may be connected to opposite or adjacent sides of the beam.

A preassembled wall panel according to the present disclosure may include a panel frame comprising a plurality of studs and at least two end members. When the wall panel is installed in a building, the end members may be horizontal members and the studs may be vertical members. The studs and end members may be orthogonal to each other. In some embodiments, the frame may be generally rectangular and the first and second end members may be disposed at opposite ends of the at least two studs. The first end member may be disposed at one end of the at least two studs and the second member may be disposed at the opposite end of the at least two studs. At least two studs may be connected to each of the first and second end members. In other embodiments, any number of studs may be arranged between the end members. In some embodiments, the frame may have different shapes and a different number of end members may be attached to the opposite ends of two or more studs.

The wall panel may also include a first wall panel connected to a first side of the panel frame. The first wall panel may fully or partially cover the first side of the frame. The wall panel may also include a second wall panel connected to a second side of the panel frame opposite the first side. The second wall panel may fully or partially cover the second side of the frame. The wall panel may include a plurality of spacers. The spacers may be attached to the wall panel. In some embodiments, a plurality of spacers may be attached to the first wall panel. In some embodiments, a plurality of spacers may be attached to the first wall panel. In some embodiments, the spacers may be attached to the first and second wall panels. The wall panel may also include a tube that may be disposed between the first and second wall panels. The tube may extend orthogonally to the end members. In some embodiments, the tube or a portion thereof may extend obliquely within the wall panel between the end members. The tube may include a tube splitter, the free end of which may pass through an opening in one of the wall panels so as to expose the opening at the free end to the exterior of the wall panel.

In some embodiments, at least one wall of a wall panel may provide the interior wall of a unit. A wall finish may be installed on the inside, for example, by fastening, gluing, or otherwise attaching one or more finish panels to the wall panel. In some embodiments, the finish panel is attached to a spacer to define a cavity between the finish panel and the wall sheathing. The cavity may house utilities. For example, one or more pipe fittings may be located behind the finish panel and partially or completely enclosed within the cavity, which may enhance the aesthetic appearance of the building interior. Similarly, the wall finish may be installed on the opposite side of the panel, which may be the other interior or exterior side. In some embodiments, connections between pipes in adjacent wall panels may be made on either side of the panel. In some embodiments, the wall panel may contain both plumbing and electrical services. In some embodiments, the wall panel may contain other utilities such as telecommunications equipment, air ducts, heating, ventilation, and air conditioning (HVAC) equipment, fire sprinkler systems, radiant heat piping, and/or drainage piping. According to the present invention, connections between utility lines in adjacent panels can be formed, and the connections can be at least partially concealed behind the finish panel.

The panels can be constructed to comply with one or more of the following building codes: fire; energy; barrier; life safety; and sound (impact and ambient noise transmission). The panels can also be constructed to comply with social and/or religious codes as needed. In some embodiments, preassembled utility panels can be considered to be fully integrated subassemblies that meet fire, sound impact, energy, and life/safety codes. In some embodiments, utility panels can be fully integrated with electrical, fire protection, energy isolation, and sound isolation capabilities. Utility panels can be designed to achieve fire ratings set by applicable building codes, such as a two-hour fire rating. In some embodiments, the panels can provide heating systems for building units. The materials, systems, methods, and/or apparatus can be constructed to comply with the International Building Code adopted in the jurisdiction.

The utility panels described herein can be manufactured outside a factory or shop and transported to a project job site to be attached to a structural frame, such as a structural exoskeleton, of a building. Off-site fabrication can include providing utilities, such as wiring, plumbing, HVAC, and combinations thereof, in the panels. The panels can be made in a variety of sizes, such as 8 feet by 22 feet. Smaller infill panels can be prefabricated on a project-by-project basis to complete the building wall system. At the construction site, the panels can be attached to floors, ceiling panels, end walls, removed walls, other utility walls, building utilities, or any combination thereof. The utility panels can provide support for the entire exterior and/or interior wall system, which in some embodiments can include an exterior steel frame installed on site.

The utility panel can provide both an exterior wall and an interior wall. A frame, such as a lightweight frame, can support the utility panel. In some embodiments, the interior wall is drywall, and the lightweight decorative panels are attached to the drywall. Opposite the interior wall, a frame can support an exterior wall, such as a structural insulation panel. In-wall radiant heat members, sound and energy isolation, sound isolators for acoustically separating floors, fire sprinkler systems, electrical and data cables, or any combination thereof, can be positioned between the interior and exterior walls of the utility panel. The utility panel combination can allow utilities to be distributed horizontally and vertically within the wall, which can allow a single utility panel to serve multiple units in a multi-story or multi-unit building.

The examples provided are for illustrative purposes only and should not be construed as limiting the scope of the present disclosure. Each exemplary embodiment may be practical for a particular environment such as an urban mixed-use development, a low-rise residential unit, and/or a remote community. The materials and dimensions of the various elements can be configured to comply with one or more of the following building codes: fire; energy; barriers; life safety, and sound (impact and ambient noise transmission) without departing from the scope of the principles of the present disclosure. Elements and/or systems can also be configured to comply with social and/or religious norms as needed. For example, the materials, systems, methods, and/or apparatus can be compliant with the International Building Code that has been adopted in a jurisdiction.

The present disclosure is not limited to the specific embodiments described in this application, which are intended to illustrate various aspects. As will be apparent to those skilled in the art, many modifications may be made and many embodiments may be made without departing from the spirit and scope of the present invention. In addition to those enumerated herein, functionally equivalent methods and devices within the scope of the present disclosure are apparent to those skilled in the art from the foregoing description. These modifications and embodiments are intended to fall within the scope of the appended claims. The present disclosure includes the terms of the appended claims and the full scope of equivalents granted by these claims. It should be understood that the present disclosure is not limited to specific methods, reagents, compound compositions, or biological systems, which can of course be changed. It should also be understood that the terms used herein are only used to describe the purpose of specific embodiments and are not intended to be limiting.

With respect to the use of substantially any plural and/or singular terms herein, those skilled in the art can translate from the plural to the singular and/or from the singular to the plural as appropriate to the context and/or application. For clarity, the various singular/plural permutations may be expressly set forth herein.

Those skilled in the art will understand that, in general, the terms used herein (especially in the appended claims, e.g., the bodies of the appended claims) are generally intended to be “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “comprising” should be interpreted as “including but not limited to,” etc.

Those skilled in the art will further understand that if a specific number of claim recitations is intended to be introduced, such intent will be explicitly stated in the claim, and in the absence of such a statement, no such intent exists. For example, to aid understanding, the following appended claims may contain the use of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of these phrases should not be interpreted as implying that the introduction of a claim recitation with the indefinite article "a" or "an" limits the claim recitation containing such an introduction to any particular claim containing only one embodiment of such a recitation, even if the same claim includes the introductory phrases "one or more" or "at least one" and an indefinite article such as "an" (e.g., "an" should be interpreted to mean "at least one" or "one or more"); this is also true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly stated, those skilled in the art will recognize that such a statement should be interpreted to mean at least the stated number (e.g., the bare statement "two recitations" without other modifiers means at least two recitations, or two or more recitations).

Furthermore, in those instances where a convention similar to “at least one of A, B, and C, etc.” is used, the meaning of such construction is generally what one skilled in the art would understand as a convention (e.g., “a system having at least one of A, B, and C” would include, but is not limited to, systems having A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention similar to “at least one of A, B, or C, etc.” is used, the meaning of such construction is generally what one skilled in the art would understand as a convention (e.g., “a system having at least one of A, B, or C” would include, but is not limited to, systems having A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). One skilled in the art would further understand that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the specification, claims, or drawings, should be understood to contemplate the possibility of including one, either, or both of the terms. For example, the phrase “A or B” would be understood to include the possibility of “A” or “B” or “A and B.”

In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

As will be understood by those skilled in the art, for any and all purposes, for example, with regard to providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations thereof. Any listed range can easily be confirmed to fully describe and make the same range be decomposed into at least equivalent half, one-third, one-quarter, one-fifth, one-tenth, etc. As a non-limiting example, each range discussed here can easily be decomposed into smaller ranges. As will be understood by those skilled in the art, all languages such as "at most," "at least," "greater than," "less than," etc. include stated quantities and refer to the ranges that can subsequently be decomposed into subranges as described above. Finally, as will be understood by those skilled in the art, ranges include each individual member. Therefore, for example, a group with 1 to 3 items refers to a group with 1, 2, or 3 items. Similarly, a group with 1 to 5 items refers to a group with 1, 2, 3, 4, or 5 items, etc.

The subject matter described herein sometimes illustrates the different components contained in or connected with other different components.Should be understood that the architecture described in this way is merely an embodiment, and in fact many other architectures that realize the same function can be implemented.In a conceptual sense, the arrangement of any components that realize the same function is effectively "associated" so that the desired function is realized.Therefore, any two components that are combined to realize a specific function herein can be considered as "associated" to each other without considering architecture or intermediate components so that the desired function is realized.Similarly, any two components that are so associated can also be considered as "operably connected" or "operably coupled" to each other to realize the desired function, and any two components that can be so associated can also be considered as "operably coupled" to each other to realize the desired function.Specific embodiments that can be operably coupled include but are not limited to physically pairable and/or physically interacting components and/or wirelessly interacting and/or wirelessly interacting components and/or logically interacting and/or logically interacting components.

Although various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and not limitation, with the true scope and spirit being indicated by the following claims.

Claims (23)

1. A pre-assembled wall panel, the wall panel comprising: A plate frame comprising a plurality of studs and a first end member and a second end member, wherein the first end member is disposed at one end of the studs and the second end member is disposed at the opposite end of the studs, and wherein each of the plurality of studs is connected to the first end member and the second end member; A first wall panel is connected to a first side of the plate frame; A second wall panel is connected to a second side of the panel frame opposite to the first side; A plurality of spacers are attached to at least one of the first wall panel and the second wall panel, wherein each of the plurality of spacers is configured to support the end panel in a relationship spaced apart from the at least one of the first wall panel and the second wall panel; A pipe, disposed between the first and second wall panels and extending between the opposite end members, wherein the pipe includes a pipe splitter, and wherein the free end of the pipe splitter passes through an opening in either the first or second wall panel, and A pipe support member is attached to the plate frame transversely to the stud, wherein the pipe support member includes a C-shaped metal channel, and wherein the wall panel further includes a conduit clamp operably engaging the C-shaped metal channel and the pipe. 2. The wall panel according to claim 1, wherein the pipe distributor comprises a pipe fitting connected to or integrally formed with the pipe segment. 3. The wall panel according to claim 2, wherein the pipe fitting includes one of a T-shaped element and a Y-shaped element. 4. The wall panel according to claim 1, wherein the opposite end of the tube is covered. 5. The wall panel according to claim 1, wherein the tube support member is connected to a track, the track is connected to at least two adjacent studs, and wherein the C-shaped metal channel is received in the track. 6. The wall panel according to claim 1, wherein the pipe is one of a plurality of water supply pipes and drain pipes that are at least partially enclosed between the first wall panel and the second wall panel. 7. The wall panel according to claim 6, wherein each of the water pipes includes a first pipe splitter and a second pipe splitter near opposite ends of the pipe, and at least one intermediate pipe splitter disposed between the first pipe splitter and the second pipe splitter. 8. The wall panel according to claim 1, wherein at least one of the first wall panel and the second wall panel comprises a plurality of prefabricated non-combustible material panels. 9. The wall panel of claim 1, wherein the plurality of spacers comprises a plurality of cap-shaped channels, each of the plurality of cap-shaped channels being arranged along a corresponding horizontal line along the length of the pre-assembled wall panel, and wherein: A first spacer and a second spacer, forming two consecutive horizontal lines between two spacers of the plurality of spacers, define a horizontal cavity between the first spacer and the second spacer. The horizontal cavity is large enough to accommodate public facilities that extend horizontally within the cavity and connect to other public facilities of at least one other pre-assembled wall panel horizontally adjacent to the pre-assembled wall panel. The final trim panel covers the horizontal cavity to conceal the public facilities housed within it. 10. The wall panel of claim 1, wherein the plurality of spacers includes a plurality of first spacers connected to the first wall panel and a plurality of second spacers connected to the second wall panel, and wherein the height of the first spacers is greater than the height of the second spacers. 11. The wall panel according to claim 1, wherein the spacer is vertically arranged and defines a plurality of vertically extending cavities, at least one of the cavities having a width greater than the height of a structural beam of the building. 12. The wall panel of claim 1, wherein the length of the wall panel is from about 18 feet to about 22 feet. 13. The wall panel of claim 1, wherein the wall panel includes an opening configured to receive a door for a unit. 14. A multi-story building, comprising: A structural frame, comprising at least one beam; and A pre-assembled wall panel, which is connected to the structural frame and includes an upper panel portion extending above the floor surface of the upper unit of the building and a lower panel portion extending below the ceiling surface of the lower unit of the building. The pre-assembled wall panel includes: A pipe located at least partially inside the pre-assembled wall panel, wherein the pipe includes a shunt exposed outside the pre-assembled wall panel; A plate frame, comprising multiple studs; and A pipe support member is attached to the plate frame transversely to the stud, wherein the pipe support member includes a C-shaped metal channel, and wherein the wall panel further includes a conduit clamp operably engaging the C-shaped metal channel and the pipe. 15. The building of claim 14, wherein the pre-assembled wall panels are configured to provide piping facilities for both the upper and lower units. 16. The building of claim 14, wherein the pre-assembled wall panel further comprises a first wall panel and a second wall panel spaced apart by the plurality of studs, wherein the pipe is arranged between the first wall panel and the second wall panel, and wherein the diverter passes through one of the first wall panel and the second wall panel. 17. The building of claim 14, wherein the pre-assembled wall panel further includes an insulator disposed perpendicular to the wall panel between the upper panel portion and the lower panel portion. 18. The building of claim 14, wherein the upper slab portion spans the entire height of the upper floor and a portion of the height of another floor above the upper floor. 19. The building of claim 14, wherein the wall panel is attached to the at least one beam, and wherein the building further comprises a floor, the floor being attached to the beam opposite to the wall panel. 20. A method for constructing a public utility wall of a building, the method comprising: The first pre-assembled wall panel is attached to the structural frame of the building; The second pre-assembled wall panel is vertically positioned above the first pre-assembled wall panel, wherein each of the first pre-assembled wall panel and the second pre-assembled wall panel comprises: A pipe located at least partially inside the wall panel, wherein the pipe includes a shunt exposed outside the wall panel; A plate frame, comprising multiple studs; and A pipe support member is attached to the plate frame transversely to the stud, wherein the pipe support member includes a C-shaped metal channel, and wherein the wall panel further includes a conduit clamp operably engaging the C-shaped metal channel and the pipe; The second pre-assembled wall panel is attached to the structural frame of the building; and Connect pipe fittings to each of the splitters to fluidly connect the pipes of the first pre-assembled wall panel and the pipes of the second pre-assembled wall panel. 21. The method of claim 20, wherein attaching the first pre-assembled wall panel to the structural frame comprises mechanically connecting the corner brackets attached to the first pre-assembled wall panel to horizontal structural members of the building. 22. The method of claim 20, wherein the first pre-assembled wall panel includes an upper panel portion and a lower panel portion, the upper panel portion extending above the floor surface of the upper unit of the building, the lower panel portion extending below the ceiling surface of the lower unit of the building, and wherein the method further includes attaching a floor to the structural frame at a location between the upper panel portion and the lower panel portion before attaching at least one of the first pre-assembled wall panel and the second pre-assembled wall panel to the structural frame. 23. The method of claim 20, wherein the pipe of each of the first pre-assembled wall panel and the second pre-assembled wall panel further includes a second diverter, and wherein the method further includes connecting a sanitary appliance to the second diverter.