US20110239548A1

US20110239548A1 - Modular construction system

Info

Publication number: US20110239548A1
Application number: US13/126,338
Authority: US
Inventors: Jean-Paul Laurent
Original assignee: Calder SARL
Current assignee: Calder SARL
Priority date: 2008-10-29
Filing date: 2009-10-29
Publication date: 2011-10-06
Also published as: EP2347057B1; WO2010049656A1; FR2937659A1; DK2347057T3; ES2435565T3; PL2347057T3; EP2347057A1; FR2937658A1

Abstract

The invention relates to a modular construction system comprising a system in which the carcass results from the juxtaposition and/or stacking assembly of a plurality of prefabricated units (1), each of said units (1) including a framework made up of the juxtaposition in coaxial alignment of multiple elements forming a frame (2), spaced two-by-two and assembled by means of bottom girders (30) and top girders (31). The top or bottom girders (30, 31, 34) of each units run along the outside of the frames (2), and each of said girders (30, 31) is designed to be securable to the equivalent girder (30, 31) of a juxtaposed unit (1); while each of the top girders (31) is designed to be capable of being shared by two stacked units (1) and of forming a bottom girder thereof.

Description

BACKGROUND OF THE INVENTION

(1) Field of the Invention
The object of this invention, in the field of building construction, is a modular construction system in which the carcass consists of several prefabricated units assembled in juxtaposition and/or in superposition.
(2) Description of the Prior Art
There are already construction systems consisting in assembling prefabricated units of various shapes, mostly cubic or parallelepipedal, deriving from the assembling of reinforced concrete walls. Besides the transportation difficulties, the weight and size of these units, as well as the implementation problems, these constructions have questionable esthetics.
There are also construction systems consisting in assembling modules having a parallelepipedal shape, by superposing them and/or by juxtaposing them. This is, for example, the case with the modules described in GB 2 334 045, which each consist of a framework made of a steel trellis composing all walls of the module, which can be assembled to others. Besides the problems that such a module can generate when it is used as a permanent or temporary residence are not easy, because of its characteristics of a metal cage, its implementation and its transportation.
Also known, from GB 2 418 437, is a construction concept which consists in juxtaposing and aligning coaxially a multiplicity of elements in the form of a frame, thus forming a module, which is designed to be assembled to another module of an identical design in order to make a building. The assembling of the frames is made through metal angles arranged externally to the angles forming in pairs said elements, whereas the assembly of two modules to each other is made through an integral connection of said angles between them by means of link devices. The disadvantage of this concept resides in that the devices for linking the modules to each other incorporate means for absorbing vibrations, which require to leave a considerable space between the modules, spaces that are capable of constituting heat bridges.

SUMMARY OF THE INVENTION

The object of this invention is to provide a prefabricated construction system permitting a fast and easy construction of a building, which favors the utilization of wood, a very economical material which is also efficient as far as insulation is concerned, and which permits to cope with the various disadvantages mentioned above.
The modular construction system according to the invention consists of a system in which the carcass is obtained by assembling, in juxtaposition and/or in superposition, several prefabricated units, each of said units comprising a framework obtained from the juxtaposition in coaxial alignment of a multiplicity of elements in the form of a frame, spaced out in pairs, and assembled through lower girders and upper girders, wherein said frames each have a lower crosspiece designed to constitute one of the supports of a floor, two lateral stiles designed to each constitute one of the supports for fixing internal and external wall panels, and at least one upper crosspiece designed to constitute one of the supports for fixing a ceiling, and it is characterized essentially in that said upper or lower girders, of each of said units, border externally said frames, and each of said girders is designed capable of being secured to the analogous girder of a juxtaposed unit; whereas each of said upper girders is designed capable of being shared by two superposed units, and of constituting a lower girder thereof.
Thus, because of the assembling characteristics of the various units to each other, there is no space between two superposed and/or juxtaposed units, so that there is no risk of creating heat bridges.
According to a particular embodiment of the modular construction system according to the invention, each of the girders has, at least on the side designed to receive the frames, a longitudinal part in the form of an angle delimiting a space designed capable of housing the junction area of a crosspiece and of a stile of a frame.
According to another additional feature of the modular construction system according to the invention, the girders comprise more than one longitudinal part in the form of an angle, in order to receive the frames of several units.
According to another particular embodiment of the modular construction system according to the invention, the frames comprise at the level of the junction area of a crosspiece and of a stile, on the external lateral side, a notch designed to receive, so as to make an integral connection by interlocking, a rib having a corresponding cross section, that the assembling girder includes longitudinally.
According to an additional feature of the modular construction system according to the invention, in a superposition of units the frames of the upper unit comprise a notch in the junction area of their lower crosspiece and of a stile, whereas the frames of the lower unit comprise a notch in the junction area of their upper crosspiece and of a stile, said notches cooperating by interlocking with the same longitudinal rib of the assembling girder.
According to an additional feature of the modular construction system according to the invention, the girders each have externally a vertical face permitting the linking to the analogous face of a girder of a juxtaposed unit.
According to another additional feature of the modular construction system according to the invention, irrespective of its embodiment, the girders comprise, arranged longitudinally, spacing elements permitting to maintain the frames spaced out from each other.
According to another additional feature of the modular construction system according to the invention, each of the frames consists of an assembly of wooden pieces.
According to another additional feature of the modular construction system according to the invention, each wooden piece designed for making a frame consists of a panel extending in the plane of the frame, and which consists of the assembling of several juxtaposed or spaced wooden pieces.
The advantages and the feature of the modular construction system according to the invention will become more evident from the description that follows, referring to the attached drawing, which represents a non-restrictive embodiment thereof.

BRIEF DESCRIPTION OF THE DRAWING

In the attached drawing:

FIG. 1 represents a partial perspective exploded schematic view of an element of the modular construction system according to the invention.

FIG. 2 represents a perspective schematic view of a part of the same system.

FIG. 3 represents a perspective schematic view of another part of the same system.

FIG. 4 represents a perspective schematic view of another part of the same system.

FIG. 5 represents a perspective schematic view of another part of the same system.

FIGS. 6 a, 6 b, 6 c and 6 d represent schematic perspective views of various embodiments of a part of the same construction system.

FIG. 7 represents a perspective schematic view of the same system in the process of implementation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, one can see a prefabricated unit 1 designed to be assembled to one or more other units in order to constitute a building in conformity with a modular construction system according to the invention.
The framework of the unit 1 consists of the juxtaposition in coaxial alignment of frames 2, spaced out in pairs and assembled by means of girders 3 arranged externally, only two of which are represented in the figure, i.e. a lower girder 30 and an upper girder 31.
The frames 2, which in the case of this figure have a rectangular shape, are each made by assembling a lower crosspiece 20, two lateral stiles 21 and 22, and an upper crosspiece 23. The integral connection of a crosspiece to a stile can be made in different ways, in particular those of the field of joinery, the crosspieces and the stiles being made of wood, the assembly being then made for example by overlapping or by means of gussets.
The girders 3 are preferably assembled with the angles of the frames 2, and are therefore adapted to permit it, they are thus in the form of an angle, and comprise on the inside a longitudinal recess E having a square cross section.
After assembling the frames 2 and the girders 3, the unit 1 can be covered. The lower crosspieces 20 can be covered with a flooring and the upper crosspieces 23 can be covered with panels forming a ceiling, whereas the stiles 21 and 22 are used as support for fixing strutting panels, both on the inside and on the outside. The space 24 left between two adjoining frames 2, should be filled up beforehand by means of an insulating material, which can possibly consist of bales of straw.
One of the advantages of the units of the construction system according to the invention consists in that there is no break between the ceiling, the lateral walls and the floor, both at the level of the frames 2 and of each of the spaces 24, so that there are no heat bridges at the angles of the unit 1.
It should be noted that this is essentially due to the fact that the girders 3 are arranged externally with respect to the frames 2.
The thickness of the elements 20, 21, 22 and 23 constituting the frames 22 can be very small, whereas their width is essentially chosen depending on the thickness one wants to give to the walls and therefore to the insulation. Said elements 20, 21, 22 and 23 can each consist of a wooden piece, massive or other, or, in case of a substantial width, of distant wooden pieces, assembled by means of crosspieces, like a ladder for example.
It should be noted that the frames 2 can have different shapes, FIGS. 6 a, 6 b, 6 c and 6 d illustrate some non-restrictive examples thereof.
Referring to FIG. 2, one can see a lower girder 30 in the form of an angle in the re-entrant angle of which are introduced the corners of the frames 2. It should be noted that the girder 30 is completed underneath by a beam 32, which is designed to rest on foundation elements F, which can consist of blocks.
Referring now to FIG. 3, one can see a girder 3, which can be just as well a lower girder 30 or an upper girder 31, that has means for spacing of the frames 2. Said spacing means each consist of a notch 33 made in the girder 3, and in which the corner of a frame 2 is located.
Said spacing means can adopt other forms, they can also consist of pieces fixed on the girder 3, on the inside.
According to the constructed building, one can superpose two units 1, in this case it is advantageous to use intermediate girders constituting for the lower unit 1 the upper girders, and for the upper unit 1 the lower girders.
In FIG. 4 one can see a part of the junction of two superposed units 1, through an intermediate girder 34. Said intermediate girder 34 has a T-shaped cross-section, it thus comprises a plank 35, which includes on the inside, longitudinally and in a substantially median position, a beam 36.
Said intermediate girder 34 can cooperate with the frames 2 in several ways. Thus, the beam 36 can have evenly spaced notches in which are located the frames 2 that are thus spaced out. The frames 2 can also include notches 25, near the upper corner for the frames 2 of the lower unit 1, and near the lower corner for the frames 2 of the upper unit 1, in which the beam 36 is fitted.
Besides, in FIG. 4 one can see that the frames 2 of the lower unit 1, are intercalated alternately with the frames 2 of the upper unit 1, yet keeping a certain distance, being positioned in the middle of the space 24. It is however possible not to leave any space and put side by side each of the frames 2 of the upper unit 1, with a frame 2 of the lower unit 1, as shown in FIG. 5.
It should be noted that in case of a juxtaposition of several units 1, the integral connection to each other is made through the integral connection of the girders 3 to each other, and in particular through their external vertical face 37.
It should also be noted that it is possible for the frames 2 of two juxtaposed units 1 to share the same girders 3, shaped as the intermediate girders described above, but used horizontally.
These assemblies permit to eliminate the risks of heat bridges between the units.
Referring now to FIG. 7, one can see a unit 1 in the process of assembling. The stiles 21 and 22 are covered externally with strutting panels 4 designed on the one hand to contribute to the rigidity of the whole, and on the other hand to cover the outside of the unit 1. Said strutting panels 4 can advantageously be oriented strand boards called “OSB”.
In this FIG. 7 one can also see that in a wall are made two types of openings capable of constituting windows or doors.
The unit 1 thus includes on the one hand openings 10 each obtained by placing between two stiles 22, of two adjoining frames 2, a lintel stiffener 26 and a breast stiffener 27; and on the other hand openings 11, extending over the full height of the unit 1, where the upper 31 and lower 30 girders constitute the lintel and the breast.
The construction system according to the invention has numerous advantages with respect to the existing constructions.
Firstly, it permits, at equal building sizes, wood savings, the used frames 2 being thin, thus reproducing the known principle of cottages.
Insulation is placed peripherally, there is no interruption at the level of angles, and therefore there are no heat bridges.
The assembling is quick and simplified, and it does not require very qualified workers. The frames 2 settle directly two right angles, the placing of a single girder 3 settles the third right angle. The girders 3 are nailed on the frames 2, whereas strutting panels 4 are nailed or stapled on the frames 2.
The units can be preassembled, transported and moved easily. They have a relatively small weight and can be lifted by the lower girders without any risk for the structure.
The materials, of course, i.e. essentially the frames 2 and girders 30 and 31, can be conveyed to the construction site, so that the units 1 can be assembled on the spot.

Claims

1. Modular construction system consisting of a system wherein the carcass is obtained by assembling in juxtaposition and/or in superposition several prefabricated units (1), each of said units (1) comprising a framework consisting of the juxtaposition in coaxial alignment of a multiplicity of elements in the form of a frame (2), spaced out in pairs, and assembled through lower girders (30, 34) and upper girders (31, 34), wherein said frames (2) each have a lower crosspiece (20) designed to constitute one of the supports of a floor, two lateral stiles (21, 22) designed to each constitute one of the supports for fixing internal and external wall panels (4), and at least one upper crosspiece (23) designed to constitute one of the supports for fixing a ceiling, the construction system is characterized in that said upper or lower girders (30, 31, 34) of each of said units, border externally said frames (2), and each of said girders (30, 31, 34) is designed capable of being secured to the analogous girder (30, 31, 34) of a juxtaposed unit (1); whereas each of said upper girders (31, 34) is designed capable of being shared by two superposed units (1), and of constituting a lower girder thereof.

2. Modular construction system according to claim 1, wherein each of the girders (30, 31, 34) has, at least on the side designed to receive the frames (2), a longitudinal part in the form of an angle delimiting a space (E) designed capable of accommodating the junction area of a crosspiece (20, 23) and of a stile (21, 22) of a frame (2).

3. Modular construction system according to claim 2, wherein the girders comprise more than one longitudinal part in the form of an angle, in order to receive the frames (2) of several units (1).

4. Modular construction system according to claim 1, wherein the frames (2) comprise at the level of the junction area of a crosspiece (20, 23) and of a stile (21, 22), on the external lateral side, a notch (25) designed to receive, so as to make an integral connection by interlocking, a rib (36) having a corresponding cross section, that the assembling girder (34) includes longitudinally.

5. Modular construction system according to claim 4, wherein in a superposition of units (1) the frames (2) of the upper unit (1) comprise a notch (25) in the junction area of their lower crosspiece (20) and of a stile (21, 22), whereas the frames (2) of the lower unit (1) comprise a notch (25) in the junction area of their upper crosspiece (23) and of a stile (21, 22), said notches (25) cooperating by interlocking with the same longitudinal rib (36) of the assembling girder (34).

6. Modular construction system according to claim 1, wherein the girders (3) comprise, arranged longitudinally, spacing elements (33) permitting to maintain the frames (2) spaced out from each other.

7. Modular construction system according to claim 1, wherein the girders (3, 30, 31, 34) each have externally a vertical face (37) permitting the linking to the analogous face of a girder (3, 30, 31, 34) of a juxtaposed unit (1).

8. Modular construction system according to claim 1, wherein each of the frames (2) consists of an assembly of wooden pieces.

9. Modular construction system according to claim 8, wherein each wooden piece designed for constituting a frame (2) consists of a panel extending in the plane of the frame (2), and which consists of the assembly of several juxtaposed or spaced wooden pieces.