WO2006000320A1 - Prefabricated wall system for constructing environments with a high degree of sterility - Google Patents

Prefabricated wall system for constructing environments with a high degree of sterility Download PDF

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Publication number
WO2006000320A1
WO2006000320A1 PCT/EP2005/006379 EP2005006379W WO2006000320A1 WO 2006000320 A1 WO2006000320 A1 WO 2006000320A1 EP 2005006379 W EP2005006379 W EP 2005006379W WO 2006000320 A1 WO2006000320 A1 WO 2006000320A1
Authority
WO
WIPO (PCT)
Prior art keywords
sheet
wall system
prefabricated wall
adhesive
fixed
Prior art date
Application number
PCT/EP2005/006379
Other languages
French (fr)
Inventor
Enrico Venturato
Original Assignee
Med S.R.L.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Med S.R.L. filed Critical Med S.R.L.
Publication of WO2006000320A1 publication Critical patent/WO2006000320A1/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/74—Removable non-load-bearing partitions; Partitions with a free upper edge
    • E04B2/7407—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts
    • E04B2/7453—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts with panels and support posts, extending from floor to ceiling
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/74—Removable non-load-bearing partitions; Partitions with a free upper edge
    • E04B2002/749—Partitions with screw-type jacks
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/74—Removable non-load-bearing partitions; Partitions with a free upper edge
    • E04B2002/7498—Partitions for clean rooms

Definitions

  • Prefabricated wall system for constructing environments with a high degree of sterility DESCRIPTION Technical field
  • the present invention relates to a prefabricated wall system for constructing environments in which a high degree of sterility is required.
  • Background Art The use of materials known as SSM, an abbreviation for Solid Surface Material, such as those known under the Corian brand produced by Dupont, or HI-MACS® produced by LG, has become widespread in the construction of hospital environments and the like.
  • a typical composition of these materials comprises polymethacrylate (acrylic resins) in percentages varying from 30% to 40%, the remaining percentage consisting of aluminium trihydrate.
  • the materials are marketed in the form of flat sheets with different thicknesses and various appearances and colours.
  • SSMs By comparison with the materials commonly used in these applications, such as timber, metal, ceramics and plastic laminates, SSMs offer numerous advantages such as high density, strength, and resistance to fire and liquid penetration. Furthermore, these materials are easily worked and suitable for thermoforming. Versions of these materials containing antibacterial agents, such as Corian AB, are also available. These characteristics make SSMs particularly suitable for the construction of walls and ceilings of operating theatres and other rooms in which a high degree of sterility is required. At present, such structures are formed by applying the Corian sheets to pre-existing walls or to suitably constructed wall framing by means of adhesives, with the interposition, if necessary, of a chipboard or plywood panel support and any necessary spacers to compensate for any misalignment of the floor or walls.
  • a primary problem relates to the fact that the joint between the Corian and the supporting structure can give rise to phenomena of swelling of the visible surfaces, due to the different coefficients of thermal expansion of the materials used.
  • walls constructed in this way frequently have to be acoustically and thermally insulated by an additional lining. It is also necessary in some cases for the operating theatre to be screened against electromagnetic fields and various types of radiation, in order to permit the use of electronic medical equipment (such as X-ray equipment), which adds to the cost and complexity of the structure.
  • the principal object of the present invention is to provide a prefabricated wall system made from SSM or similar materials which is structurally and functionally designed to overcome all the drawbacks mentioned with reference to the cited prior art.
  • Another object of the invention is to provide a wall system including a supporting structure which permits simplified installation of the system.
  • Another object of the invention is to provide a wall system which maintains a pleasing appearance over time.
  • a further object of the invention is to provide a wall system in which the joints between the floor and the walls, between the walls and the ceiling and between the adjacent walls do not introduce surface discontinuities, thus keeping the surface of the room free of crevices or sharp edges which are difficult to clean.
  • FIG. 1 is a perspective view of the interior of a room whose walls are made with a system according to the present invention
  • - Figure 2 is a sectional view of a portion of wall made according to the present invention
  • - Figure 3 is a view of the fixing system of the wall
  • - Figure 4 is an enlarged view of a detail of the wall or floor junction fillets. Best mode for carrying out the invention
  • the number 1 indicates the whole of a hospital environment such as an operating theatre, constructed with a prefabricated wall system made according to the present invention.
  • the environment 1 is made from self-supporting panels 2, junction pieces or fillets at the ceiling 3 and at the floor 4, and concave curved junction pieces 5 or convex curved junction pieces 6 where the adjacent walls form an outside corner or a dihedral angle.
  • the panels 2 are mounted on a support structure 7 of conventional design, which can comprise, as in the illustrated example, a framing of metal sections with uprights 8 and cross- pieces.
  • Each panel 2 comprises a first visible sheet 10 of SSM, typically Corian (registered trademark of Du Pont de Nemours), HI-MACS® produced by LG, or other similar material.
  • this sheet has a thickness in the range from 3 mm to 13 mm, with a preferred value of 6 mm (the original thicknesses are given in inches, as 1 A", V_>" and 3 A").
  • materials including antibacterial agents such as CorianTM AB, are used.
  • the first sheet is spot-fixed to a second sheet 11, preferably made from galvanized steel sheet.
  • the second sheet is made for this purpose with a plurality of bosses 12 in the form of identical truncated conical appendages, lying in the same direction and regularly distributed over its surface.
  • bosses are formed by pressing the sheet, and the first sheet 10 is fixed by means of an elastomeric adhesive 14, typically a low modulus silicone adhesive, to the minor base 13 of each boss.
  • an elastomeric adhesive 14 typically a low modulus silicone adhesive
  • the fastening between the first and second sheet provides a sufficient degree of freedom to absorb differences in expansion between the first and second sheet, without any substantial deformation of the panel, even though the two materials have very different coefficients of expansion.
  • bosses is a preferred solution for obtaining the desired spot-fixing between the first and second sheet, it is also possible to omit the bosses, and carry out the spot-fixing simply by the localized application of the silicone adhesive (in mushroom or drop shapes).
  • the second sheet 11 is surrounded by a frame 16 formed by bending the same sheet, and has attachment formations 17 which are preferably fitted to the frame by riveting or otherwise. They predominantly act as fixing means for fixing the panel 2 to studs 19 fitted to the cross-pieces and/or uprights of the supporting framing, so that the panel is fastened to them by means of the second sheet made from steel. It is also possible for the second sheet to be fixed to the ground by means of a skirt 20 fixed to it and to the uprights and shaped to extend under corresponding feet 21 of the uprights.
  • the panel 2 also comprises a third sheet 30, preferably made from an insulating material such as closed-cell cellular glass foam or anhydrous calcium sulphate (anhydride) panelling, commonly called “plasterboard”, or high-density orientated-fibre rock wool.
  • This third sheet 30 preferably has a thickness in the range from 13 mm to 40 mm and is applied to the opposite side of the second sheet from the first sheet, so as to be completely housed within the frame 16 which surrounds it.
  • the ceiling fillets 3 and the floor fillets 4, as well as the curved junction pieces 5 and 6, are produced by thermoforming panels of SSM sheet having a thickness substantially identical to that of the sheet 10.
  • junction pieces with large radii of curvature are produced, thus facilitating the cleaning and thorough sterilization of the room, a particularly important aspect in the hospital environment and especially in the surgical environment.
  • milled portions 31 of the sheets are provided to form profiles of reduced thickness.
  • a similar bevelled profile, but with a decreasing thickness, is formed along the edge of the floor fillet 4 to produce a suitable junction with the floor covering, typically linoleum sheet.
  • Neoprene gaskets 32 are fitted between the panels and the support structure 7, to compensate for the expansion of the panels, to exert a pre-stressing pressure during the mounting of the panels, and to improve the sound insulation of the whole structure.
  • the structure which has been described offers numerous advantages by comparison with known wall construction systems. These include the total elimination of junction pieces consisting of metal or plastics extrusions or sections, which create discontinuities in the structure and thus generally create crevices at the junction points and particularly in corners.
  • the large radii of curvature obtained by thermoforming the SSM panel also facilitate cleaning. By only thermoforming the junction pieces, in other words parts having a very limited extension, it becomes unnecessary to produce special pieces, such as panels including curves, which would be required for the normal use of these materials for public purposes.
  • the walls are stable at all temperatures, since they absorb thermal expansion without deformation.
  • Another significant characteristic is that, if environments insulated from electromagnetic radiation are to be constructed, it is simply necessary to apply a thin sheet of lead or similar insulating material to the third layer of the panels, without any further complication of the construction.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Building Environments (AREA)

Abstract

A prefabricated wall system for constructing environments with a high degree of sterility, particularly operating theatres, includes at least one self-supporting panel comprising a first sheet of solid surface material (SSM) consisting of approximately 1/3 acrylic resin and approximately 2/3 natural thermoformable mineral substances, such as the materials known under the registered trademarks CORIANTM and HI-MACS® (the latter being produced by LG), and a second metal sheet which has dimensions substantially equal to those of the first sheet and which is spotfixed to it.

Description

Prefabricated wall system for constructing environments with a high degree of sterility DESCRIPTION Technical field The present invention relates to a prefabricated wall system for constructing environments in which a high degree of sterility is required. Background Art The use of materials known as SSM, an abbreviation for Solid Surface Material, such as those known under the Corian brand produced by Dupont, or HI-MACS® produced by LG, has become widespread in the construction of hospital environments and the like. A typical composition of these materials comprises polymethacrylate (acrylic resins) in percentages varying from 30% to 40%, the remaining percentage consisting of aluminium trihydrate. The materials are marketed in the form of flat sheets with different thicknesses and various appearances and colours. By comparison with the materials commonly used in these applications, such as timber, metal, ceramics and plastic laminates, SSMs offer numerous advantages such as high density, strength, and resistance to fire and liquid penetration. Furthermore, these materials are easily worked and suitable for thermoforming. Versions of these materials containing antibacterial agents, such as Corian AB, are also available. These characteristics make SSMs particularly suitable for the construction of walls and ceilings of operating theatres and other rooms in which a high degree of sterility is required. At present, such structures are formed by applying the Corian sheets to pre-existing walls or to suitably constructed wall framing by means of adhesives, with the interposition, if necessary, of a chipboard or plywood panel support and any necessary spacers to compensate for any misalignment of the floor or walls. However, this type of wall has a considerable number of drawbacks. A primary problem relates to the fact that the joint between the Corian and the supporting structure can give rise to phenomena of swelling of the visible surfaces, due to the different coefficients of thermal expansion of the materials used. Moreover, walls constructed in this way frequently have to be acoustically and thermally insulated by an additional lining. It is also necessary in some cases for the operating theatre to be screened against electromagnetic fields and various types of radiation, in order to permit the use of electronic medical equipment (such as X-ray equipment), which adds to the cost and complexity of the structure. Moreover, the joints between the floor and the walls, between the walls and the ceiling, and between adjacent walls are conventionally formed by means of plastics or metal extrusions or sections, which however create discontinuities in the finished surface in which bacteria and dirt can easily lodge. Disclosure of the invention The principal object of the present invention is to provide a prefabricated wall system made from SSM or similar materials which is structurally and functionally designed to overcome all the drawbacks mentioned with reference to the cited prior art. Another object of the invention is to provide a wall system including a supporting structure which permits simplified installation of the system. Another object of the invention is to provide a wall system which maintains a pleasing appearance over time. A further object of the invention is to provide a wall system in which the joints between the floor and the walls, between the walls and the ceiling and between the adjacent walls do not introduce surface discontinuities, thus keeping the surface of the room free of crevices or sharp edges which are difficult to clean. These objects and others which are revealed more fully in the following description are provided by the invention by means of a prefabricated wall system made from SSM or similar materials, constructed in accordance with the following claims. Brief description of the drawings The characteristics and advantages of the invention will be made clearer by the detailed description of a preferred example of embodiment thereof, illustrated, for the purposes of guidance and without restrictive intent, with reference to the attached drawings, in which: - Figure 1 is a perspective view of the interior of a room whose walls are made with a system according to the present invention; - Figure 2 is a sectional view of a portion of wall made according to the present invention; - Figure 3 is a view of the fixing system of the wall; - Figure 4 is an enlarged view of a detail of the wall or floor junction fillets. Best mode for carrying out the invention In the figures, the number 1 indicates the whole of a hospital environment such as an operating theatre, constructed with a prefabricated wall system made according to the present invention. The environment 1 is made from self-supporting panels 2, junction pieces or fillets at the ceiling 3 and at the floor 4, and concave curved junction pieces 5 or convex curved junction pieces 6 where the adjacent walls form an outside corner or a dihedral angle. In turn, the panels 2 are mounted on a support structure 7 of conventional design, which can comprise, as in the illustrated example, a framing of metal sections with uprights 8 and cross- pieces. Each panel 2 comprises a first visible sheet 10 of SSM, typically Corian (registered trademark of Du Pont de Nemours), HI-MACS® produced by LG, or other similar material. In the illustrated example, this sheet has a thickness in the range from 3 mm to 13 mm, with a preferred value of 6 mm (the original thicknesses are given in inches, as 1A", V_>" and 3A"). Preferably, materials including antibacterial agents, such as Corian™ AB, are used. The first sheet is spot-fixed to a second sheet 11, preferably made from galvanized steel sheet. The second sheet is made for this purpose with a plurality of bosses 12 in the form of identical truncated conical appendages, lying in the same direction and regularly distributed over its surface. These bosses are formed by pressing the sheet, and the first sheet 10 is fixed by means of an elastomeric adhesive 14, typically a low modulus silicone adhesive, to the minor base 13 of each boss. Thus the fastening between the first and second sheet provides a sufficient degree of freedom to absorb differences in expansion between the first and second sheet, without any substantial deformation of the panel, even though the two materials have very different coefficients of expansion. Although the formation of bosses is a preferred solution for obtaining the desired spot-fixing between the first and second sheet, it is also possible to omit the bosses, and carry out the spot-fixing simply by the localized application of the silicone adhesive (in mushroom or drop shapes). The second sheet 11 is surrounded by a frame 16 formed by bending the same sheet, and has attachment formations 17 which are preferably fitted to the frame by riveting or otherwise. They predominantly act as fixing means for fixing the panel 2 to studs 19 fitted to the cross-pieces and/or uprights of the supporting framing, so that the panel is fastened to them by means of the second sheet made from steel. It is also possible for the second sheet to be fixed to the ground by means of a skirt 20 fixed to it and to the uprights and shaped to extend under corresponding feet 21 of the uprights. The panel 2 also comprises a third sheet 30, preferably made from an insulating material such as closed-cell cellular glass foam or anhydrous calcium sulphate (anhydride) panelling, commonly called "plasterboard", or high-density orientated-fibre rock wool. This third sheet 30 preferably has a thickness in the range from 13 mm to 40 mm and is applied to the opposite side of the second sheet from the first sheet, so as to be completely housed within the frame 16 which surrounds it. The ceiling fillets 3 and the floor fillets 4, as well as the curved junction pieces 5 and 6, are produced by thermoforming panels of SSM sheet having a thickness substantially identical to that of the sheet 10. By thermoforming these panels, junction pieces with large radii of curvature are produced, thus facilitating the cleaning and thorough sterilization of the room, a particularly important aspect in the hospital environment and especially in the surgical environment. To improve the joint between the contact edges of the first sheets 10 of the panels 2 and the fillets and junction pieces 3, 4, 5 and 6, milled portions 31 of the sheets are provided to form profiles of reduced thickness. A similar bevelled profile, but with a decreasing thickness, is formed along the edge of the floor fillet 4 to produce a suitable junction with the floor covering, typically linoleum sheet. Neoprene gaskets 32 are fitted between the panels and the support structure 7, to compensate for the expansion of the panels, to exert a pre-stressing pressure during the mounting of the panels, and to improve the sound insulation of the whole structure. The structure which has been described offers numerous advantages by comparison with known wall construction systems. These include the total elimination of junction pieces consisting of metal or plastics extrusions or sections, which create discontinuities in the structure and thus generally create crevices at the junction points and particularly in corners. The large radii of curvature obtained by thermoforming the SSM panel also facilitate cleaning. By only thermoforming the junction pieces, in other words parts having a very limited extension, it becomes unnecessary to produce special pieces, such as panels including curves, which would be required for the normal use of these materials for public purposes. Moreover, the walls are stable at all temperatures, since they absorb thermal expansion without deformation. Another significant characteristic is that, if environments insulated from electromagnetic radiation are to be constructed, it is simply necessary to apply a thin sheet of lead or similar insulating material to the third layer of the panels, without any further complication of the construction.

Claims

CLAIMS 1. Prefabricated wall system for constructing environments (1) with a high degree of sterility, particularly operating theatres, including at least one self-supporting panel (2) comprising a first sheet (10) of solid surface material (SSM) consisting of approximately 1/3 acrylic resin and approximately 2/3 natural thermoformable mineral substances, such as the materials known under the registered trademarks CORIAN™ and HI-MACS® (the latter being produced by LG), characterized in that the said at least one panel comprises a second metal sheet (11) which has dimensions substantially equal to those of the first sheet and which is spot-fixed to the said first sheet. 2. Prefabricated wall system according to Claim 1, in which the second sheet is spot-fixed to the first sheet by means of an elastomeric adhesive (14). 3. Prefabricated wall system according to Claim 2, in which the said adhesive is a low modulus silicone adhesive. 4. Prefabricated wall system according to any one or more of the preceding claims, in which the second sheet (11) is provided with a plurality of bosses (12) spaced apart from each other, and the adhesive (14) is interposed between the bosses and the first sheet. 5. Prefabricated wall system according to any one or more of the preceding claims, in which a third sheet (30) of insulating material is provided and is fixed to the opposite side of the second sheet (11) from the first sheet (10). 6. Prefabricated wall system according to Claim 5, in which the said insulating material is selected from anhydrous calcium sulphate (anhydride) (plasterboard), closed-cell cellular glass foam, and high-density orientated-fibre rock wool. 7. Prefabricated wall system according to any one or more of the preceding claims, in which the second sheet (11) has means (17) for fixing to a support structure (7). 8. Prefabricated wall system according to Claim 7, in which the said fixing means (17) form a fastening with at least one degree of freedom. 9. Prefabricated wall system according to any one or more of the preceding claims, comprising concave or convex junction pieces (5,6) made from a solid surface material thermoformed with a large radius of curvature for covering the edges between the floor and the wall, between one wall and the next, and between the walls and the ceiling. 10. Prefabricated wall system according to any one or more of the preceding claims, in which the support structure is provided with a skirt (20) which can be fixed to the floor. 11. Prefabricated wall system according to any one or more of the preceding claims, in which a further sheet of material with electromagnetic radiation insulation properties, such as lead, is placed behind the third sheet, or in which the lead sheet is incorporated directly into the sheet of anhydride or closed-cell cellular glass fibre or high-density orientated-fibre rock wool. 12. Prefabricated wall system according to any one or more of the preceding claims, in which the said first sheet (10) contains an antibacterial agent.
PCT/EP2005/006379 2004-06-24 2005-06-15 Prefabricated wall system for constructing environments with a high degree of sterility WO2006000320A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITPD2004A000165 2004-06-24
ITPD20040165 ITPD20040165A1 (en) 2004-06-24 2004-06-24 SYSTEM OF PREFABRICATED WALLS FOR THE CONSTRUCTION OF HIGH ASEPTIC WALLS

Publications (1)

Publication Number Publication Date
WO2006000320A1 true WO2006000320A1 (en) 2006-01-05

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WO (1) WO2006000320A1 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020012484A3 (en) * 2018-07-11 2020-02-20 Veev Group, Inc. Prefabricated construction wall assembly
US11085185B2 (en) 2018-10-22 2021-08-10 Qclass S.A. Modular panel system and a wall installation method

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5094057A (en) * 1990-01-16 1992-03-10 Morris Phillip L Anchor for simulated marble panels and the like
WO1997049761A1 (en) * 1996-06-26 1997-12-31 E.I. Du Pont De Nemours And Company Antibacterial solid surface materials
GB2377714A (en) * 2001-07-17 2003-01-22 Komfort Office Environments A stud assembly for room dividing panels
US6550203B1 (en) * 2001-04-19 2003-04-22 Radiation Protection Products, Inc. Leak-proof lead barrier system

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5094057A (en) * 1990-01-16 1992-03-10 Morris Phillip L Anchor for simulated marble panels and the like
WO1997049761A1 (en) * 1996-06-26 1997-12-31 E.I. Du Pont De Nemours And Company Antibacterial solid surface materials
US6550203B1 (en) * 2001-04-19 2003-04-22 Radiation Protection Products, Inc. Leak-proof lead barrier system
GB2377714A (en) * 2001-07-17 2003-01-22 Komfort Office Environments A stud assembly for room dividing panels

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020012484A3 (en) * 2018-07-11 2020-02-20 Veev Group, Inc. Prefabricated construction wall assembly
US11885124B2 (en) 2018-07-11 2024-01-30 Veev Group, Inc. Prefabricated construction wall assembly
US11085185B2 (en) 2018-10-22 2021-08-10 Qclass S.A. Modular panel system and a wall installation method

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