AU2016231625A1 - Building Module System - Google Patents

Description

2 2016231625 23 Sep 2016 “Building Module System”

Field of the Invention [001] The present invention relates to a system for constructing housing.

Background to the Invention [002] The cost of constructing buildings in remote areas can be significantly higher than construction costs in urban areas. Factors influencing these costs include the cost of transportation of materials and costs associated with having tradespeople travel to and stay at the remote location.

[001] Given the high cost of building in such areas, it is necessary to employ techniques to reduce on-site building time in order to ensure that the cost of building is affordable. Constructing buildings of pre-made modules is therefore common. Such modules are generally transported on trucks and connected together on site. The module’s length and width are also sized to reduce transport costs. For example, modules beyond a specified width require escort vehicles and permits, which substantially increases the transport costs, thereby affecting the overall project cost.

[002] The present invention relates to a building module system comprising such prefabricated structural modules. The system is aimed at providing adaptable construction while reducing transport costs.

Summary of the Invention [003] According to one aspect of the present invention there is provided a building module system for forming a structure comprising: a plurality of modules, each comprising an upper ring member supported above a lower ring member by a plurality of uprights; a plurality of upper interconnecting members; and 3 2016231625 23 Sep 2016 a plurality of lower interconnecting members; wherein the upper interconnecting members are secured between the upper ring member of a module and the upper ring member of an adjacent module and the lower interconnecting members are secured between the lower ring member of a module and the lower ring member of the adjacent module such that a living space of the structure is formed between the adjacent modules.

[004] Preferably the modules are rectangular prism in shape such that the upper and lower ring members comprises first and second sides and first and second ends.

[005] Preferably the uprights comprise elongate members secured at lower ends to an upper surface of the lower ring member and at upper ends to a lower surface of the upper ring member, at intervals around the upper and lower ring members.

[006] In a preferred embodiment, the structure is formed from a pair of modules located such that the first side of the upper and lower ring members of a first of the modules are adjacent and parallel the second side of the upper and lower ring members of a second of the modules.

[007] In one embodiment, first ends of the first and second modules are generally collinear and the second ends of the first and second modules are also generally collinear.

[008] In a preferred embodiment, upper surfaces of the lower interconnecting members are aligned with upper surfaces of the lower ring members of the modules such that upper surfaces of the lower ring members and the lower interconnecting members can be used for mounting a floor of the structure.

[009] Preferably lower surfaces of the upper connecting interconnecting members are aligned with lower surfaces of the upper ring members of the modules such that lower surfaces of the upper ring members and the upper interconnecting members can be used for mounting a ceiling of the structure. 4 2016231625 23 Sep 2016 [010] In one embodiment, a multiple level structure is formed by stacking further modules on top of the modules placed on the base, such that the lower ring members of the further modules are placed on top of the upper ring members of the modules on the base.

[011] Preferably the modules are provided with wall panels extending between the upper and lower ring members.

[012] In a preferred embodiment, corner brackets are provided to secure corners of adjacent modules, the corner brackets comprising a first side portion securable to a side member of one of the ring members, a second side portion securable to an end member of the ring member and a post connection member between the first and second side portions for securing to a post of the module.

[013] Preferably the first and second side portions comprise a U-shaped member receivable in an end of a channel in the adjacent side or end member.

[014] In a preferred embodiment, each of the first and second side portions of the corner connector comprises a central wall portion and upper and lower transverse wall portions such that, in use, the central wall portion is located adjacent a side wall of the side or end member, the upper transverse wall portion is located adjacent an upper flange or the side or end member and the lower transverse wall portion is located adjacent a lower flange of the side or end member.

[015] Preferably each of the central wall portion and the upper and lower wall portions includes holes to receive fasteners to secure the corner bracket to the side or end members.

[016] In a preferred embodiment, the post connection member comprises an L-shaped plate to receive adjacent sides of one of the posts.

[017] Preferably side brackets are provided to connect together side or end members of adjacent modules at locations away from the corners. 5 2016231625 23 Sep 2016 [018] Preferably the side bracket comprises U-shaped brackets such that the side brackets include a central wall portion and upper and lower wall portions.

[019] Preferably the side brackets are provided with a support rib extending along the central wall portion between the upper and lower wall portions.

Brief Description of the Drawings [003] The invention will now be described, by way of example, with reference to the following drawings in which: [004] Figure 1 is a view of a structure constructed in accordance with the present invention; [005] Figure 2 is a view of a two level structure constructed in accordance with the present invention; [006] Figure 3 is a view of the structure of Figure 1 utilising wall panels; [007] Figure 4a is an upper perspective view of a corner bracket for use with the building module system; [008] Figure 4b is a top view of the corner bracket of Figure 4a; [009] Figure 4c is a front view of the corner bracket of Figure 4a; [010] Figure 4d is a side of the corner bracket of Figure 4a; [011] Figure 5a is an upper perspective view of a side bracket for use with the building module system; [012] Figure 5b is a top view of the side bracket of Figure 5a; [013] Figure 5c is a front view of the side bracket of Figure 5a; [014] Figure 5d is a side view of the side bracket of Figure 5a; [015] Figure 6a is a perspective view of a floor formed from the lower ring member of a module; [016] Figure 6b is a view showing three connected modules of the building module system; [017] Figure 7a is a close up view of Detail A of Figure 6a; [018] Figure 7b is a top view showing connection between corners of adjacent modules; [019] Figure 7c is a close up view of Detail C of Figure 6b; and 6 2016231625 23 Sep 2016 [020] Figure 8 is a close up view of Detail B of Figure 6a.

Detailed Description of Preferred Embodiments [021] Referring to the Figures, there is shown a building module system for creating a structure 10 to be used, for example, as a residential dwelling. The building system comprises a plurality of modules 12 and a plurality of upper and lower interconnecting members 14 and 15.

[022] Each of the modules 12 comprises a lower ring member 16 and an upper ring member 17. The lower ring member 16 is to be mounted in use on a base 18 and the upper ring member 17 is to be supported above the lower ring member 16 by a plurality of uprights 20.

[023] In the embodiment shown the modules 12 are rectangular prisms in shape. The upper and lower ring members 16 and 17 are therefore rectangular comprising first and second sides 22 and 23 and first and second ends 24 and 25. The first and second sides 22 and 23 and the first and second ends 24 and 25 are secured together at ends thereof to form a solid rectangular structure.

[024] The uprights 20 comprise elongate members secured at lower ends to the lower ring member 16 and at upper ends to the upper ring member 17. The uprights 20 extend vertically from upper surfaces of the lower ring member 16 to lower surfaces of the upper ring member 17 at regular intervals around the upper and lower ring members 16 and 17. The upper and lower ring members 16 and 17 and the uprights 20 are to be formed of a suitable metallic material.

[025] The structure 10 is to be formed by a plurality of modules 12. The modules 12 are located adjacent each other such that a space is formed between the adjacent modules 12. In the embodiment shown in Figure 1, the structure 10 is formed from a pair of modules 12 located such that the first sides 22 of the upper and lower ring members 16 and 17 of a first module are adjacent and parallel to the second sides 23 of the upper and lower ring 7 2016231625 23 Sep 2016 members 16 and 17 of the second module 12. In the embodiment shown, the first ends 24 of the first and second modules 12 are generally collinear and the second ends 25 of the first and second modules 12 are also generally collinear. It will be appreciated however that the ends 24 and 25 of the modules 12 may be offset and other configurations may also be possible.

[026] The lower interconnecting members 14 are provided to be connected between the lower ring member 16 of the first module 12 and the lower ring member 16 of the second module 12. The lower interconnecting members 14 are connected to be perpendicular to the first and second sides 22 and 23 of the adjacent modules 12. The lower interconnecting members 14 are of the same height as the lower ring members 16 such that upper surfaces of the lower ring members 16 and the lower interconnecting members 14 can be used for mounting of a floor of the structure 10.

[027] The upper interconnecting members 15 are provided to be connected between the upper ring member 17 of the first module 12 and the upper ring member 17 of the second module 12. The upper interconnecting members 15 are connected to be perpendicular to the first and second sides 22 and 23 of the adjacent modules 12. The upper interconnecting members 15 are of the same height as the upper ring members 17 such that lower surfaces of the upper ring members 17 and the upper interconnecting members 15 can be used for mounting of a ceiling of the structure 10.

[028] The upper and lower interconnecting members 14 and 15 thereby define an area which can be used as a living space of the structure 10. Wall panels (not shown) may be secured between the upper and lower ring members 16 and 17 and the upper and lower interconnecting members 14 and 15 at appropriate locations to define outer and inner walls of the structure 10. As shown, roofing elements 28 may be mounted to upper surfaces of the upper ring members 17 and the upper interconnecting members 15 to form a roof structure of the structure 10. Further, extension members 30 may be secured to extend outwardly from the outer surfaces of the lower ring members 16 to define an outdoor floor area, for example to be used as a veranda. 8 2016231625 23 Sep 2016 [029] As shown in Figure 2, a multiple level structure 10 may be formed by stacking further modules 12 on top of the modules 12 placed on the base 18. The lower ring members 16 of the further modules 12 are placed on top of the upper ring members 17 of the modules 12 provided on the base 18. The lower ring members 16 of the upper modules 12 are secured to the upper ring members 17 of the lower modules 12.

[030] Upper and lower interconnecting members 14 and 15 may also be provided extending between the upper modules 12 to define living spaces on the upper level.

[031] The modules 12 of the present invention are expected to be constructed of a width suitable for transport on a truck. The building system provides for construction of dwellings of greater area than that of the base area of the modules 12. The upper and lower ring members 16 and 17 also provide suitable points to which lifting cables may be secured for moving the modules 12 on and off the transport vehicle and also to upper level locations on top of base modules 12.

[032] Figure 3 shows a further embodiment of a structure 10 in accordance with the present invention. The embodiment of Figure 3 is similar to the embodiment of Figure 1 and like reference numerals are used to denote like parts.

[033] In the embodiment of Figure 3, the modules 12 are provided with wall panels 32. The wall panels 32 are formed from a plurality of elongate members to form rectangular planar frames. The wall panels 32 are secured between the lower and upper ring members 16 and 17 to provide additional strength to the modules 12. The wall panels 32 are provided on the first and second sides 22 and 23 of the modules 12 such that the wall panels 32 extend along the lengths thereof.

[034] In some structures 10, some of the modules 12 may be connected directly to other modules 12. Figure 6b shows an example of a connection between three such modules 12 which may be used within a structure. 9 2016231625 23 Sep 2016 [035] The connections between modules 12 may be formed by a plurality of brackets, including corner brackets 40 and side brackets 41. As can be seen in Figure 6a, the ring members 16 and 17 are formed from separate elongate members comprising the sides 22 and 23 and the ends 24 and 25. That is, the ring member 16 or 17 is formed from first and second side members 42 and 43 and first and second end members 44 and 45 The corner brackets 40 connect adjacent side and end members at the corner of the ring members 16 and 17 and allow also for connection to an upright 20 located at the corner.

[036] The corner brackets 40 comprise a first side portion 46 connectable to an end of the first or second side member 42 or 43 and a second side portion 47 connectable to the first of second end member 44 or 45. Each of the first and second side portions 46 and 47 extends outwardly from a post connection member 48 provided to receive an end of a post 20.

[037] The first and second side portions 46 and 47 each comprise a U-shaped member received an end of a channel in the adjacent side or end member 42, 43, 44, 45. Each of the side and end members 42, 43, 44 and 45 comprises generally a C-channel such that the side and end members 42, 43, 44, 45 each include a side wall 49 having transverse upper and lower flanges 50 and 51. Each of the first and second side portions 46 and 47 of the corner bracket 40 comprises a central wall portion 52 and upper and lower transverse wall portions 53 and 54 such that, in use, the central wall portion 52 is located adjacent the side wall 49, the upper transverse wall portion 53 is located adjacent the upper flange 50 and the lower transverse wall portion 54 is located adjacent the lower flange 51. Each of the central wall portion 52 and the upper and lower wall portions 52 and 53 includes holes 62 to receive fasteners to secure the corner bracket 40 to the side or end members 42, 43, 44 and 45.

[038] The post connection member 48 comprises an L-shaped plate 56 to receive adjacent sides of one of the posts 20. The post 20 may be secured to the L-shaped plate 56 by appropriate means, such as welding. 10 2016231625 23 Sep 2016 [039] As can be seen in Figure 7b, when the corners of adjacent modules 12 are placed together, the first side portions 46 of adjacent corner brackets 40 align such that the fasteners (not shown) may be passed through the aligned holes 62, thereby securing together the corner brackets 40, and therefore the modules 12.

[040] As shown in Figure 7b, if the corner of a module 12 is located adjacent the side of a further module 12, a connection plate 58 is placed adjacent the side wall 49 of the side member 42 or 43. The connection plate 58 includes holes 62 to align with the holes 62 in the central wall portion 52 of the first or second side portion 46 or 47 of the corner bracket 41. Fasteners (not shown) thereby connect the connection plate 58 through to the corner bracket 40.

[041] The side brackets 41 may be used to connect together side or end members 42, 43, 44, 45 of adjacent modules 12 at locations away from the corners. The side bracket 41 comprise U-shaped brackets such that the side brackets 41 include a central wall portion 52 and upper and lower wall portions 53 and 54. The side brackets 41 are securable to the side or end members 42, 43, 44, 45 as shown in Figure 8 and connected to a further side bracket 41, or connection plate 58 provided within the side or end member 42, 43, 44, 45 of an adjacent module 12.

[042] The side brackets 41 are provided with a support rib 60 extending along the central wall portion 52 between the upper and lower wall portions 53 and 54. The support rib 60 is provided to give extra support between the upper and lower wall portions 53 and 54 to resist bending.

[043] When modules 12 are stacked on top of each other, the upper wall portions 54 of the corner or side brackets 40 or 41 align with the lower wall portions 53 of the corner of side brackets 40 or 41 in the above module 12. Fasteners are then received through the aligned holes 62 to secure the corner or side brackets 40 or 41 together.

[044] It will be readily apparent to persons skilled in the relevant arts that various modifications and improvements may be made to the foregoing 11 2016231625 23 Sep 2016 embodiments, in addition to those already described, without departing from the basic inventive concepts of the present invention.

Claims (17)

1. The claims defining the invention are as follows:

   1. A building module system for forming a structure comprising: a plurality of modules, each comprising an upper ring member supported above a lower ring member by a plurality of uprights; a plurality of upper interconnecting members; and a plurality of lower interconnecting members; wherein the upper interconnecting members are secured between the upper ring member of a module and the upper ring member of an adjacent module and the lower interconnecting members are secured between the lower ring member of a module and the lower ring member of the adjacent module such that a living space of the structure is formed between the adjacent modules.
2. 2. A building module system in accordance with claim 1, wherein the modules are rectangular prism in shape such that the upper and lower ring members comprises first and second sides and first and second ends.
3. 3. A building module system in accordance with claim 2, wherein the uprights comprise elongate members secured at lower ends to an upper surface of the lower ring member and at upper ends to a lower surface of the upper ring member, at intervals around the upper and lower ring members.
4. 4. A building module system in accordance with claim 3, wherein the structure is formed from a pair of modules located such that the first side of the upper and lower ring members of a first of the modules are adjacent and parallel the second side of the upper and lower ring members of a second of the modules.
5. 5. A building module system in accordance with claim 4, wherein first ends of the first and second modules are generally collinear and the second ends of the first and second modules are also generally collinear.
6. 6. A building module system in accordance with claim 5, wherein upper surfaces of the lower interconnecting members are aligned with upper surfaces of the lower ring members of the modules such that upper surfaces of the lower ring members and the lower interconnecting members can be used for mounting a floor of the structure.
7. 7. A building module system in accordance with claim 6, wherein lower surfaces of the upper connecting interconnecting members are aligned with lower surfaces of the upper ring members of the modules such that lower surfaces of the upper ring members and the upper interconnecting members can be used for mounting a ceiling of the structure.
8. 8. A building module system in accordance with claim 7, wherein a multiple level structure is formed by stacking further modules on top of the modules placed on the base, such that the lower ring members of the further modules are placed on top of the upper ring members of the modules on the base.
9. 9. A building module system in accordance with any one of the preceding claims, wherein the modules are provided with wall panels extending between the upper and lower ring members.
10. 10. A building module system in accordance with any one of the preceding claims, wherein corner brackets are provided to secure corners of adjacent modules, the corner brackets comprising a first side portion securable to a side member of one of the ring members, a second side portion securable to an end member of the ring member and a post connection member between the first and second side portions for securing to a post of the module.
11. 11. A building module system in accordance with claim 10, wherein the first and second side portions comprise a U-shaped member receivable in an end of a channel in the adjacent side or end member.
12. 12. A building module system in accordance with claim 11, wherein each of the first and second side portions of the corner connector comprises a central wall portion and upper and lower transverse wall portions such that, in use, the central wall portion is located adjacent a side wall of the side or end member, the upper transverse wall portion is located adjacent an upper flange or the side or end member and the lower transverse wall portion is located adjacent a lower flange of the side or end member.
13. 13. A building module system in accordance with claim 12, wherein each of the central wall portion and the upper and lower wall portions includes holes to receive fasteners to secure the corner bracket to the side or end members.
14. 14. A building module in accordance with claim any one of claims 10 to 13, wherein the post connection member comprises an L-shaped plate to receive adjacent sides of one of the posts.
15. 15. A building module system in accordance with any one of the preceding claims, side brackets are provided to connect together side or end members of adjacent modules at locations away from the corners.
16. 16. A building module system in accordance with claim 15, wherein the side bracket comprises U-shaped brackets such that the side brackets include a central wall portion and upper and lower wall portions.
17. 17. A building module system in accordance with claim 16, wherein the side brackets are provided with a support rib extending along the central wall portion between the upper and lower wall portions.