AU2010202951A1

AU2010202951A1 - Modular construction system

Info

Publication number: AU2010202951A1
Application number: AU2010202951A
Authority: AU
Inventors: Brian Ernest Reid; Edward John Reid
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-07-13
Filing date: 2010-07-13
Publication date: 2011-01-27

Description

AUSTRALIA PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT (ORIGINAL) Name of Applicant: Brian Ernest Reid Actual Inventors: Brian Ernest Reid and Edward John Reid Address for Service: DAVIES COLLISON CAVE, Patent Attorneys, Level 3, 303 Coronation Drive, Milton 4064, Queensland. Invention Title: "Modular construction system" Details of Associated Provisional Applications Nos: Australian Provisional Patent Application No. 2009903267, filed 13 July 2009 The following statement is a full description of this invention, including the best method of performing it known to us: \NR,,,orthl\DCCsEwo\36480_i DOC-7/13/20110 MODULAR CONSTRUCTION SYSTEM Background of the Invention 5 This invention relates to a modular construction system and related elements, namely a panel member, an elongate key element, an elongate mounting portion, and a roof truss. Description of the Prior Art 10 Reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that the prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to 15 which this specification relates. Existing building methods typically rely on timber or similar panels fastened to a timber or metal framework, which is generally a labour intensive and time-consuming process. One disadvantage of such known methods is poor thermal performance, where additional energy is 20 necessary to maintain an inside of a structure built in this manner at a desired temperature level. This is commonly due to heat entering or escaping the structure through convection and/or conduction. The current invention seeks to propose a possible improvement to the existing construction 25 systems.

1C rRPortl\CsD|\3064800)- IX)C-7113/2010 -2 Summary of the Present Invention According to a first aspect of the invention, there is provided a modular construction system including: 5 a number of panel members each including a frame portion which defines at least one longitudinal channel along a side thereof, the channel having an outwardly tapering profile section; at least one elongate mounting portion for mounting the panel members to a surface, the mounting portion being operatively fastened to said surface and defining a longitudinal 10 channel having an outwardly tapering profile section; and at least one elongate key element having a mirrored dovetail profile section, the key element slidably receivable into the channels of the frame portion and the mounting portion when said channels overlap, wherein the key element and the channels interact in a complementary friction fit manner to secure the panel members to the mounting portion. 15 Typically each panel member includes panels sandwiching the frame portion. Typically, the panels are manufactured from fibre reinforced magnesium silicate board. 20 Typically, the frame portion is manufactured from fibre reinforced polyurethane foam. Typically, the mounting portion is manufactured from fibre reinforced polyurethane foam. Typically, the key element is manufactured from fibre reinforced polyurethane foam. 25 Typically, the modular construction system includes a number of attachment portions defining at least one channel having an outwardly tapering profile section, said attachment portions -3 useable to arrange the panel members, mounting portion and key element into different arrangements. Typically, the modular construction system includes a roof truss arrangement. 5 Typically, the modular construction system includes fasteners for fastening elements of the construction system in place. According to a second aspect of the invention, there is provided a panel member for a modular 10 construction system, the panel member including: two sheets each having a corrugated side fastened together so that respective furrows and ridges overlap to define internal channels; and an insulation sheet sandwiched between the ridges of the sheets to span across said channels, wherein edges of the respective sheets interact to define a longitudinal channel 15 having an outwardly tapering profile section along at least one side of the panel member. Typically, the sheets are manufactured from fibre reinforced polyurethane foam. Typically, the insulation sheet includes a thermal insulation material. 20 Typically, the insulation sheet includes an acoustic insulation material. Typically, the sheets are fastened together with an adhesive. 25 Typically, the panel member includes spacing members sandwiched between the ridges to increase a width of the panel member.

C:NRPonDCC \0048txk1DOC-7/1312010 -4 According to a third aspect of the invention, there is provided an elongate key element for a modular construction system, the key element defining a mirrored dovetail profile section to be slidably receivable into a channel complementarily defined by overlapping portions of the construction system, said portions each defining a channel having an outwardly tapering 5 profile section, wherein the key element fits inside the channel in a friction fit manner to secure the portions together. Typically, the key element is manufactured from fibre reinforced polyurethane foam. 10 According to a fourth aspect of the invention, there is provided an elongate mounting portion for a modular construction system, the mounting portion being operatively fastenable to a surface and defining a longitudinal channel having an outwardly tapering profile section, said channel for complementarily interacting with a similarly shaped channel defined by another portion of the modular construction system, in order to receive an elongate key element to 15 secure the portion to the mounting portion in a friction fit manner. Typically, the elongate mounting portion is manufactured from fibre reinforced polyurethane foam. 20 According to a fifth aspect of the invention, there is provided a roof truss for a modular construction system, the roof truss including a number of fibre reinforced polyurethane foam beams gang-nailed together, at least one beam defining a longitudinal channel along a side thereof, the channel having an outwardly tapering profile section, said channel for complementarily interacting with a similarly shaped channel defined by another portion of the 25 modular construction system, in order to receive an elongate key element to secure the roof truss to the portion in a friction fit manner.

C:\NRPonhNX'CuiEH\364 )DOC-7/13/2010 -5 According to a sixth aspect of the invention, there is provided a panel member for a modular construction system, the panel member including: a frame define a longitudinal channel having an outwardly tapering profile section along at least one side of the panel member for receiving an elongate key element; and, 5 an insulation sheet mounted within the frame. Typically the panel member includes a sheet mounted to one side of the frame. Typically the sheet includes a fibre cement sheet. 10 Typically the insulation sheet includes a thermal insulation material. Typically, in use, the frame is fastened to at least one stud of a building. 15 Brief Description of the Drawings An example of the present invention will now be described with reference to the accompanying drawings, in which: Figure 1 shows a schematic side sectional representation of one example of elements of 20 a modular construction system; Figure 2 shows a schematic side sectional view of the elements of Figure 1, in use; Figure 3 shows a schematic front view of the elements of the modular construction system of the preceding Figures; Figure 4 shows a schematic front view of the elements on Figure 3, in use; 25 Figure 5 shows a schematic top sectional representation of a further example of elements of the modular construction system; Figure 6 shows a schematic front view of the elements of the modular construction system of Figure 5; &C:RhronblDCCWsaf)6448xjI I)UC-7/1/2010 -6 Figure 7 shows a schematic front view of the elements on Figure 5, in use; Figures 8A to 8F show schematic side sectional representations of examples of different attachment portions of the modular construction system; Figure 9 shows a schematic front view of examples of further elements of the modular 5 construction system; Figure 10 shows a schematic side sectional representation of a panel member; Figure I1 shows a schematic side sectional representation of a further example of the panel member of Figure 11; Figure 12A and 12B show schematic side sectional representations of additional 10 examples of the elements of the construction system; Figure 13A shows a schematic front view of a construction system including a further example of a panel member; Figure 13B shows a cross sectional view of the panel members of Figure 13A along the line A-A'; and, 15 Figure 14 shows a cross sectional plan view of a construction system including a further example of a panel member. Detailed Description of Preferred Examples 20 With reference now to the accompanying drawings, there is shown an example of a modular construction system 10. Figure 1 shows a side-sectional view of a surface 22, such as a concrete slab or similar foundation structure on which a building can be erected. The surface 22 can also include a load-bearing pillar or column. Also shown is an elongate mounting portion 20 in cross section. The mounting portion 20 is operatively fastened to the surface 22 25 in any suitable manner, such as via adhesives, fasteners, e.g. bolts, rivets, nails, or the like, etc. As shown, the mounting portion 20 defines a longitudinal channel 24 extending along a length thereof with this channel 24 having an outwardly tapering profile section.

AC kNJ'-bMN)C EIN1U64KW)_I DOC.7/132011) -7 The system 10 also typically includes a number of panel members, with one such member indicated by reference numeral 12. The panel member 12 includes panels 14 sandwiching a frame portion 16 which defines at least one longitudinal channel 18 along a side thereof, as shown. This channel 18 also defines an outwardly tapering profile section. 5 The system 10 further includes an elongate key element 26 having a mirrored dovetail profile section, as shown. The key element 26 is shaped to be slidably receivable into the channels 18 and 24 of the frame portion 16 and the mounting portion 20 when said channels 18 and 24 overlap. The key element 26 and the channels 18 and 24 interact in a complementary friction 10 fit manner to secure the panel member 12 to the mounting portion 20, as described in more detail below. However, additionally the key 26 can be held in position using structural polyurethane glue, thereby helping to ensure that the joint is water and air tight. The panels 14 are typically manufactured from fibre reinforced magnesium silicate board. 15 However, in further arrangements the panels 14 may be manufactured from a number of different materials, such as drywall, gyprock, fibre cement, ply sheeting, timber, or the like. Fibre reinforced magnesium silicate board is highly resistant to climatic conditions, is non combustible and non-flammable, moisture resistant as well as dimensionally stable. Fibre reinforced magnesium silicate board also offers a chemically stable material which has 20 excellent thermal and acoustic performance levels. Similarly, the frame portion 16, the mounting portion 20 and the key element 24 are typically manufactured from fibre reinforced polyurethane foam. This material has a high level of thermal performance, including a fire rating performance ideally suited to the built 25 environment, and has a low coefficient of thermal expansion minimizing stresses on joints due to environmental temperature fluctuations to which constructions are typically subjected. Fibre reinforced polyurethane foam is also water, vermin and termite proof, whilst offering good load bearing capability.

*C:\NRb D)CC\I1a\364800)( tDOC-7/1/20 0 -8 Figure 2 shows the panel member 12 secured to the mounting portion 20 via the key element 26 interacting with the channels 18 and 24 in a complementarily friction-fit manner. The mirrored dovetail cross-section of the key element 26 forms a structurally stable joint between 5 the panel member 12 and the mounting portion 20, as shown. Together with the low coefficient of thermal expansion of the materials comprising the frame portion 16, the key element 26 and the mounting portion 20, the joint so formed finds particular application in the built environment. 10 Figure 3 shows the constructions system 10 in front view. In the shown arrangement, two panel members 12 each have a key element 26 for securing the respective panel members to the mounting portion 20 fastened to the surface 22. As described above, each panel member 12 includes a frame portion 16 defining a channel 18. In this example, the frame portion 16 defines such channels 18 having an outwardly tapering profile section on each side of the 15 panel member 12, as shown. It is to be appreciated that the panel member 12, and typically the frame portion 16, further includes additional structural support 17, such as studs and/or nogging-type portions, as shown. This additional structural support 17 is only indicated on one panel member 12. 20 Accordingly, Figure 4 shows a panel member 12 being secured to the mounting portion 20. The panel member 12 is placed on the mounting portion 20 so that the respective channels 18 and 24 overlap, after which the key element 26 is slid into the channel formed by the overlapping channels 18 and 24. 25 Figure 5 shows an example of a manner in which two panel members 12 can be fastened together by means of the key element 26. In this arrangement, both frame portions 16 of the respective panel members 12 define a channel 18, as shown. When the panel members 12 are placed side-by-side, the channels 18 overlap and can received the key element 26.

*C.\NRPrthl\DCC\SEIRu)64x0_ 1C-7/3/2010 -9 Figure 6 shows a front view of the panel members 12 of Figure 5. Similar to the arrangement described with reference to Figure 4 above, the panel members 12 can be secured to the mounting portion 20 so that the side-by-side channels 18 of the respective panel members 12 5 overlap. The key element 26 can then be inserted into the channels 18, as shown in Figure 7, to secure the panel members 12 together. In addition, as shown in Figure 8, the modular construction system 10 generally also includes a number of attachment portions 28. These attachment portions 28 typically define at least one 10 channel having an outwardly tapering profile section, as shown. The attachment portions 28 can be used to arrange the panel members 12, mounting portion 20 and key elements 26 into different arrangements. For example, the attachment portion 28 shown in Figure 8A can be used to form an angle between two panel members 12. The attachment portion 28 of Figure 8D can be used as a column support for fastening four panel members together. Similarly, the 15 different attachment portions 28 can be used for a number of different applications. Figure 9 shows a further example of the modular construction system 10 which includes fasteners 30 for fastening elements of the construction system 10 in place. In the shown arrangement, the fasteners 30 include rods for fastening the panel members 12 and the 20 mounting portion 20 together and to the surface 22. It is to be appreciated that any different manner of fastener 30 can be used depending on which element (panel member 12, mounting portion 20, key element 26, etc.) requires fastening to another element. In addition, in one arrangement, the construction system 20 also includes a roof truss 32. The 25 roof truss 32 typically includes a number of fibre reinforced polyurethane foam beams (not shown) gang-nailed together, with at least one beam defining a longitudinal channel 34 along a side thereof, as shown. The channel 34 also has an outwardly tapering profile section, similar to the channels 18 and 24. Similar to the above described arrangements, the channel 34 can be C WNRPonN)CC.SElIf"648)t DOC-7/13/21110 - 10 overlapped with the channels 18 in order to secure the roof truss 32 to the panel members 12, or other elements of the construction system 10. Similarly, fasteners 30 can be used to fasten the roof truss 32 to other elements of the system 10. 5 It is further to be appreciated that the construction system 10 can also be used in constructing flooring. In such an example (not shown), the panel members 12 are placed substantially horizontally on a sub-frame structure and secured together using the key elements 26, as described above. 10 Figure 10 shows another example of a panel 40 which can be used with the construction system 10. The panel 40 includes two sheets 42 each having a corrugated side fastened together so that respective furrows 46 and ridges 48 overlap, as shown. The overlapping corrugations define internal channels 50. The panels 40 further includes insulation sheets 52 sandwiched between the ridges 48 of the sheets 42 to span across the internal channels 50, as 15 shown. Additionally, edges 54 of the respective sheets 42 interact to define a longitudinal channel 56 which has an outwardly tapering profile section similar to the panel members 12 described above. As above, the sheets 42 are typically manufactured from fibre reinforced polyurethane foam. 20 The insulation sheets are generally manufactured from a thermal insulation material and/or an acoustic insulation material to provide increased thermal and/or acoustic insulative properties to the panel 40. The sheets 42 are generally fastened together using a suitable adhesive. Figure Il shows a further arrangement of the panel 40 of Figure 10. The panel 40 includes 25 spacing members 58 sandwiched between the ridges 48 of the sheets to increase a width of the panel 40, as shown. This arrangement provides a way to easily produce a panel 40 of varying thickness which can be used with the construction system 10, as described above.

C RIoIhN)CC MEI 64810 I )OC-7/13/2O0 - 11 It is to be appreciated that various modifications to the above-described examples are possible. For instances, Figure 12 shows further examples of the panel members 12, where the panels 14 are arranged in different arrangements on the frame portion 16, as shown. Figure 12A shows an arrangement where the frame portion 16 and the panels 14 of the panel member 12 is 5 arranged to fit over the mounting portion 20. Similarly, Figure 12B shows an arrangement where the mounting portion 20 is shaped and configured for receiving a portion of the panel member 12. Accordingly, the different elements of the construction system 10 can be altered whilst still falling inside the scope of the invention. 10 Figures 13A and 13B show a further arrangement of a panel member. The panel member 12 includes a frame 16 which defines at least one longitudinal channel 18 defines an outwardly tapering profile section. In this example, the channel 18 extends around the perimeter of the frame 16, allowing the frame to be connected to other wall panels 12 or a mounting portion 20, using an elongate key element 26. However, the channel need only extend along at least 15 one side, depending on connectivity requirement. The frame 16 includes an insulation panel 60 mounted therein. The insulation panel can be any form of insulation panel, but in one example includes NRG Greenboard TM wall cladding, which can be used to provide enhanced thermal, fire insulation or the like. This can be used to 20 ensure that a wall incorporating the wall panel meets necessary building code requirements. In the event that the wall panel is not being used to provide load bearing capabilities, the wall panel member does not necessarily include sheets 14, although these can be included in a manner substantially as described above with respect to the previous examples. 25 The panel can be connected to a frame of a framed building as shown in Figure 14. In this example, the building includes a frame having one or more timber or metal studs 70. The studs typically have insulation 72 positioned therebetween, as well as having a layer of foil 4C:\N)hl\DCC\S1:1K,8Wl-IX)C.7/13/210 - 12 insulation 74, such as SisalationTM, provided thereon. The wall panel members 12 are substantially as described with respect to Figure 13A and 13B, and can be attached to the studs 72 using any suitable technique, such as bolting through the frame, or the like. In this example, the wall panel includes a sheet 62 mounted to one of the sides. The sheet is intended 5 to form an outer surface of the building, and can be formed from fibre cement sheet, or the like. The use of a sheet allows the wall to provide additional properties, such as fire resistance, thereby ensuring that the wall meets necessary building fire code requirements. Additionally, 10 the sheet can be used to provide a desired appearance, such as cladded, rendered, or corrugated. The above-described examples provide for a modular construction system 10 which includes a number of elements allowing for a flexible and diverse number of different constructions. The 15 system 10 provides for easy assembly of the elements which have excellent thermal performance, as well as fire-resistance and environmental performance. Persons skilled in the art will appreciate that numerous variations and modifications will become apparent. All such variations and modifications which become apparent to persons 20 skilled in the art should be considered to fall within the spirit and scope of the invention broadly appearing and described in more detail herein. It is to be appreciated that reference to "one example" or "an example" of the invention is not made in an exclusive sense. Accordingly, one example may exemplify certain aspects of the 25 invention, whilst other aspects are exemplified in a different example. These examples are intended to assist the skilled person in performing the invention and are not intended to limit the overall scope of the invention in any way unless the context clearly indicates otherwise.

4 C \RPonbl\DCC jifLI064WX00.I DO)C-7/11rinto - 13 Features that are common to the art are not explained in any detail as they are deemed to be easily understood by the skilled person. Similarly, throughout this specification, the term "comprising" and its grammatical equivalents shall be taken to have an inclusive meaning, unless the context of use clearly indicates otherwise.

Claims

1. A modular construction system including: a number of panel members each including a frame portion which defines at least one 5 longitudinal channel along a side thereof, the channel having an outwardly tapering profile section; at least one elongate mounting portion for mounting the panel members to a surface, the mounting portion being operatively fastened to said surface and defining a longitudinal channel having an outwardly tapering profile section; and 10 at least one elongate key element having a mirrored dovetail profile section, the key element slidably receivable into the channels of the frame portion and the mounting portion when said channels overlap, wherein the key element and the channels interact in a complementary friction fit manner to secure the panel members to the mounting portion. 15 2. The modular construction system of claim 1, wherein each panel member includes panels sandwiching the frame portion.

3. The modular construction system of claim 2, wherein the panels are manufactured from fibre reinforced magnesium silicate board. 20

4. The modular construction system of any one of the claims I to 3, wherein the frame portion is manufactured from fibre reinforced polyurethane foam.

5. The modular construction system of any one of claims I to 4, wherein the 25 mounting portion is manufactured from fibre reinforced polyurethane foam.

6. The modular construction system of any one of claims 1 to 5, wherein the key element is manufactured from fibre reinforced polyurethane foam. 4c :kWrthl\DCC\S~ftIO648(XIX)C-7/13/2010 - 15

7. The modular construction system of any one of claims I to 6, which includes a number of attachment portions defining at least one channel having an outwardly tapering profile section, said attachment portions useable to arrange the panel members, mounting 5 portion and key element into different arrangements.

8. The modular construction system of any one of claims I to 7, which includes a roof truss arrangement. 10 9. The modular construction system of any one of claims I to 8, which includes fasteners for fastening elements of the construction system in place.

10. A panel member for a modular construction system, the panel member including: 15 two sheets each having a corrugated side fastened together so that respective furrows and ridges overlap to define internal channels; and an insulation sheet sandwiched between the ridges of the sheets to span across said channels, wherein edges of the respective sheets interact to define a longitudinal channel having an outwardly tapering profile section along at least one side of the panel member. 20 I1. The panel member of claim 10, wherein the sheets are manufactured from fibre reinforced polyurethane foam.

12. The panel member of either one of claims 10 or 11, wherein the insulation sheet 25 includes a thermal insulation material.

13. The panel member of any one of claims 10 to 12, wherein the insulation sheet includes an acoustic insulation material. SC:\NRrb\DN)CC\SEIN\)648U_ IX)C-7/13/20 10 -16

14. The panel member of any one of claims 10 to 13, wherein the sheets are fastened together with an adhesive. 5 15. The panel member of any one of claims 10 to 14, which includes spacing members sandwiched between the ridges to increase a width of the panel member.

16. An elongate key element for a modular construction system, the key element defining a mirrored dovetail profile section to be slidably receivable into a channel 10 complementarily defined by overlapping portions of the construction system, said portions each defining a channel having an outwardly tapering profile section, wherein the key element fits inside the channel in a friction fit manner to secure the portions together.

17. The key element of claim 16, which is manufactured from fibre reinforced 15 polyurethane foam.

18. An elongate mounting portion for a modular construction system, the mounting portion being operatively fastenable to a surface and defining a longitudinal channel having an outwardly tapering profile section, said channel for complementarily interacting with a 20 similarly shaped channel defined by another portion of the modular construction system, in order to receive an elongate key element to secure the portion to the mounting portion in a friction fit manner.

19. The elongate mounting portion of claim 18, which is manufactured from fibre 25 reinforced polyurethane foam.

20. A roof truss for a modular construction system, the roof truss including a number of fibre reinforced polyurethane foam beams gang-nailed together, at least one beam *CINP,,bWCC SI M{)64WX I IEOC.7IM2)I - 17 defining a longitudinal channel along a side thereof, the channel having an outwardly tapering profile section, said channel for complementarily interacting with a similarly shaped channel defined by another portion of the modular construction system, in order to receive an elongate key element to secure the roof truss to the portion in a friction fit manner. 5

21. A panel member for a modular construction system, the panel member including: a frame define a longitudinal channel having an outwardly tapering profile section along at least one side of the panel member for receiving an elongate key element; and, an insulation sheet mounted within the frame. 10

22. The panel member of claim 21, wherein the panel member includes a sheet mounted to one side of the frame.

23. The panel member of claim 22, wherein the sheet includes a fibre cement sheet. 15

24. The panel member of any one of the claims 21 to 23, wherein the insulation sheet includes a thermal insulation material.

25. The panel member of any one of claims 21 to 24, wherein, in use, the frame is fastened 20 to at least one stud of a building.

26. A modular construction system, a panel member, an elongate key element, an elongate mounting portion, or a roof truss substantially as hereinbefore described 25 27. A modular construction system, a panel member, an elongate key element, an elongate mounting portion, or a roof truss substantially as hereinbefore described and illustrated with reference to the accompanying drawings. * * *|