CN110268123B

CN110268123B - Modular construction system

Info

Publication number: CN110268123B
Application number: CN201780083011.2A
Authority: CN
Inventors: D·J·裴
Original assignee: Concept Modular Ltd
Current assignee: Concept Modular Ltd
Priority date: 2017-01-11
Filing date: 2017-01-11
Publication date: 2022-01-14
Anticipated expiration: 2037-01-11
Also published as: CN110268123A; EP3568536A1; PH12019550126A1; EP3568536A4; WO2018129673A1; US20190383001A1; AU2017392352A1; JP2020504257A

Abstract

A joining system for connecting a first building construction element and a second building construction element is provided. The system includes a female snap (18), the female snap (18) being connected to a first building construction element (14) and including first and second female snap-receiving surfaces (20, 22), wherein the first and second female snap-receiving surfaces (20, 22) generally face away from each other and are adjacent an axis-defining aperture (24). The system further comprises a male snap (32), the male snap (32) being connected to a second building construction element (16) and comprising a first and a second male snap clamping surface (33, 34), wherein the first and second male snap clamping surfaces (33, 34) generally face each other. A male buckle (32) is inserted through the aperture (24) and moved in a first transverse direction to grip the female buckle (18). The locking device (42) includes first and second locking structures (44, 46), the first and second locking structures (44, 46) engaging to allow movement of the male buckle (32) in a first transverse direction to increase clamping force on the female buckle (18) and inhibit movement opposite the first transverse direction.

Description

Modular construction system

Technical Field

The present invention relates to modular construction systems, and in particular to construction members for connecting such as walls and roof members and systems and methods for supporting bottom panels.

Background

Modular construction systems have been proposed, but assembling modular construction systems into buildings is often time consuming and may require a significant amount of work to be done on site. It would be desirable to provide a modular construction system that reduces the amount of finishing work required at the building assembly site and is relatively easy to assemble.

Disclosure of Invention

In one aspect, a joining system for connecting a first building construction element and a second building construction element is provided. The coupling system includes a female snap (female dog) connectable to a first building construction element and including a first female snap receiving surface and a second female snap receiving surface. The first and second female snap-receiving surfaces generally face away from each other and are adjacent a male snap (male dog) through-hole defining a hole axis. The joining system further comprises a male snap-on connectable to a second building construction element and comprising a first male snap-on clamping surface and a second male snap-on clamping surface. The first and second male snap-fit clamping surfaces generally face each other. A portion of the male snap may be inserted through the male snap through-hole and movable in a first generally transverse direction to grip the female snap. The binding system also includes a locking device including a first locking structure on the female buckle and a second locking structure on the male buckle. The first locking structure is engageable with the second locking structure to allow movement of the male buckle in a first lateral direction to increase a clamping force of the male buckle on the female buckle and to inhibit movement of the male buckle in a second generally lateral direction opposite the first generally lateral direction.

In another aspect, a bottom support system is provided that includes a cross beam and a bottom support member. The cross beam extends horizontally. The cross beam has a top wall, a bottom wall, and side walls, and has an interior at least partially defined by the top wall, the bottom wall, and the side walls. The side wall has a plurality of bottom support through slots that are horizontally spaced from one another. The bottom support member includes a vertical portion extending upwardly from the slot in the interior and proximate the side wall and a horizontal portion extending outwardly through the slot to support the bottom panel.

In yet another aspect, a top panel joining system is provided that includes a bolt, a top panel support member, and a top panel. The bolt has a bolt thread. The top panel support member extends generally horizontally and has a side wall with a top panel side wall bolt hole therethrough. The top panel support member has a bolt retaining surface positioned to support the bolt against lateral movement. The top panel has top panel side walls that are mateable with the side walls of the top panel support member. The top panel has a top panel threaded hole therethrough. The bolt extends through the top panel threaded hole through the side wall of the top panel support member. At least one of the top panel and the top panel support member has an access hole to allow access of the bolt to allow rotation of at least one of the bolt and the top panel threaded hole relative to the other of the bolt and the top panel threaded hole to drive the top panel side wall into abutment with the top panel support member side wall.

In yet another aspect, a joining system for joining a first wall panel and a second wall panel is provided. The joining system comprises a first support plate connected to the first wall panel, and a second support plate connected to the second wall panel, a first clamping surface on the first support plate, and a second clamping surface on the second support plate. The coupling system further includes a threaded member having a first end located in the first end chamber, wherein the threaded member passes through the first support member, through the second wall panel, and through the second support plate, wherein the first end abuts the first clamping surface. The second end has a nut thereon which can be tightened against the second support plate to clamp the second wall panel to the first wall panel.

Drawings

FIG. 1 is a perspective view of a building, with a portion cut away, and including one or more modifications, according to an embodiment of the present invention;

FIG. 2 is a side sectional view of a portion of the building shown in FIG. 1, showing a modification which is a joining system for joining first and second construction elements;

FIG. 3 is a side sectional view of another portion of the building shown in FIG. 1, showing a joining system connecting different first and second construction members;

FIG. 4 is a perspective view of an enlarged portion of FIG. 1, showing the bonding system shown in FIGS. 2 and 3;

FIG. 5 is a perspective exploded view of the binding system shown in FIGS. 2 and 3;

6A-6F are cross-sectional side views illustrating the engagement of the female and male snaps included in the bonding system shown in FIGS. 2 and 3;

7A-7C are cross-sectional side views illustrating the engagement of variations of the female and male snaps included in the bonding system shown in FIGS. 2 and 3;

FIG. 8 is a perspective view of two top panels from the building shown in FIG. 1;

FIG. 9 is a cross-sectional elevation view according to a connection between a top panel and a top panel support member incorporated into a top panel joining system according to another embodiment of the present invention;

FIG. 10 is a perspective view of a portion of the top panel support member shown in FIG. 9;

FIG. 11 is an exploded perspective cut-away view of two wall panels that may be joined together using the joining system shown in FIG. 2;

FIG. 12 is a cross-sectional elevation view of first and second wall panels connected by a wall panel joining system that may be advantageously used in the building shown in FIG. 1;

FIG. 13 is a cross-sectional elevation view of a bottom support system that may be advantageously used in the building shown in FIG. 1;

FIG. 14 is a perspective view of the base support system shown in FIG. 13; and

FIG. 15 is a perspective view of an alternative to a portion of the base support system shown in FIG. 13.

Detailed Description

Referring to fig. 1, there is shown a building 10, the building 10 being constructed at least in part from modular components and which includes one or more of several improvements. A first modification is shown in fig. 2-5 and 6A-6F and is a joining system, shown generally at 12, for connecting a first building construction element 14 and a second building construction element 16. For example, as shown in fig. 2, the first building construction component 14 may be a top panel and the second building construction component 16 may be a triangular wall panel. Alternatively, as shown in fig. 3, the first building construction component 14 may be a top panel and the second building construction component may be another type of wall panel.

The joining system 12 includes a female snap 18, the female snap 18 being connectable to the first building construction element 14 and including a first female snap receiving surface 20 and a second female snap receiving surface 22. The first and second female snap-receiving

surfaces

20 and 22 generally face away from each other and are adjacent a male snap-through hole 24 defining a bore axis a (fig. 5). Male-type snap through-holes 24 may be defined in a generally laterally extending female-type snap base 25. Female snap base 25 may also have a second female snap receiving surface 22 thereon.

The first female snap-receiving surface 20 may be provided on a female snap tab 26, the female snap tab 26 extending generally perpendicular to the female snap base 25. Female snap tab 26 may be secured to female snap base 25 by any suitable means. For example, female snap tab 26 may have a stud that extends into a mounting hole in female snap base 25 and may be secured by welding, by press fit, or by any other suitable means.

The female luer 18 extends inwardly in the first construction member into a female luer cavity 27 (fig. 2 and 3) defined in the first construction member 14. The female snap-on chamber 27 may be provided by a length of hollow section pipe, shown at 28, such as for example a square hollow section steel pipe, which forms part of the first construction member 14. The hollow section tube 28 may be configured as a frame surrounding a core panel 29 which may be made of EPS (expanded polystyrene) (fig. 7A fig. 7C). The core panel can be made using different construction methods and materials, including cross-laminated panel and conventional stub construction panel technologies. The frame and core panels 29 may be covered on both the upper and lower surfaces with an outer surface layer 30 of MgO having a finished surface as is known for shell construction. A layer of top sheet 31 may be placed on the top panel. The top sheet may be, for example, any suitable material, such as, for example, corrugated board, which may be made of a polymeric material or a metallic material.

The joining system 12 further comprises a male snap 32, the male snap 32 being connectable to the second building construction element 16 and comprising a first male snap clamping surface 33 and a second male snap clamping surface 34. The first and second male snap-fit clamping surfaces 33 and 34 generally face each other. A portion 36 of the male snap 32 is insertable through the male snap through-hole 24 (as shown in fig. 6A-6B) and is movable in a first generally transverse direction (as shown by arrow D1 in fig. 6C-6E) to grip the female snap 18. The male snap 32 includes a male snap base 38, the male snap base 38 extending generally transversely and having a second male snap-clamping surface 34 thereon. The male snap 32 may also include a male snap tab 40, with the male snap tab 40 extending generally perpendicular to the male snap base 38. Male snap tab 40 may be mounted to the male snap base by any suitable means, such as any of the means described above for securing female snap tab 26 to female snap base 25.

The binding system 12 also includes a locking device 42 that includes a first locking structure 44 on the female buckle 18 and a second locking structure 46 on the male buckle 32. The first locking structure 44 is engageable with the second locking structure 46 to allow the male buckle 32 to move in a first transverse direction to increase the clamping force of the male buckle 32 on the female buckle 18 and to inhibit movement of the male buckle 32 in a second generally transverse direction opposite the first generally transverse direction.

In the embodiment shown in fig. 2-5 and 6A-6F, the first locking structure 44 includes a detent 48 (in the form of a detent plate) on the female buckle 18 and the second locking structure includes a plurality of male buckle teeth 50. In this embodiment, the locking device 42 also includes a pawl biasing member 52, the pawl biasing member 52 urging the pawl 48 toward engagement with the male buckle teeth 50. The pawl biasing member 52 may be in the form of a plurality of coil springs 54 (or may be any other suitable type of biasing member). Coil spring 54 is shown mounted on shoulder bolt 56, shoulder bolt 56 extending through female snap base 25 and pawl 48 and retained thereon with nut 58. Washer 60 is shown supporting pawl 48 in spaced relation to female snap base 25.

Fig. 6A-6F illustrate the progression of movement of male snap 32 through aperture 24 and fully engaged with female snap 18. As can be seen, when the male buckle 32 is moved in direction D1, the pawl 48 is pushed downward into engagement with each tooth 50, allowing further movement in direction D1 while preventing movement in a second direction opposite direction D1.

It should be noted that when the first and

second construction members

14 and 16 are joined together, they may not be joined in such a manner that the male snaps reach the position shown in FIG. 6F. For example, it may only reach the position shown in fig. 6D or fig. 6E. However, over time, as building 10 settles, any vibration or movement applied to the male or female fastener in the direction of D1 will cause the male fastener 32 and female fastener 18 to advance toward the position shown in fig. 6F (i.e., toward progressively greater engagement), and any vibration or other movement applied to the male fastener 32 and female fastener 18 in a direction away from D1 will not cause the male fastener 32 and female fastener 18 to move. Thus, assuming that settlement and other events of building 10 will promote movement in substantially all directions over time, eventually the engagement between male snaps 32 and female snaps 18 may increase, which will strengthen building 10 and will improve the "perpendicularity" of the joints between the various construction members making up the building.

Fig. 7A-7C illustrate a modified progressive engagement of male 32 and female 18 snaps with locking device 42, wherein first locking structure 44 includes a plurality of female snap-fit teeth 52 on first female snap-fit receiving surface 20, and second locking structure 46 includes a plurality of male snap-fit teeth 54 on first male snap-fit clamping surface 33, wherein female 52 and male 54 snap-fit teeth extend generally axially and may intersect one another in a generally axial/transverse plane (which is the plane shown in the views of fig. 7A-7C).

In the embodiment shown in fig. 7A-7C, the first and

second construction members

14 and 16 are top panels that are joined together in a lap joint, as can be better seen in fig. 8. The top panels are identified at 58 and 60. The top panel 58 has a first extension 62 and the top panel 60 has a second extension 64 that overlaps the first extension 62. When joining the

top panels

58 and 60, the first top panel 58 is placed on the support structure of the building and then slid upwardly into position until its upper edge engages a ridge structure or other top panel support member (an example of which is shown at 66 in fig. 9 and 10). The process of abutting the top panel with the ridge structure is described further below. Once the top panel 58 is placed adjacent to the top panel support member, the top panel 60 is placed with its extended portion 64 on top of the extended portion 62 of the first top panel 58 to form a lap joint. The male snap 32 is disposed on the extension 64 and protrudes downwardly, while the female snap 18 is disposed in the extension 62 of the top panel 58. When the top panel 60 is installed, it is such that the male snap 32 is inserted downwardly through the hole 24 in the female snap 18 (FIG. 7A). The top panel 60 is then slid upward to drive it toward abutment with a top panel support member (such as member 66), which also brings the male-type snaps 32 into progressively greater engagement with the female-type snaps 18 as shown in the cross-sectional side views of fig. 7A-7C.

Referring to fig. 11, which shows a first wall panel 68 that may be the first construction component 14 and have a plurality of female snaps 18 thereon, and a second wall panel 70 that may be the second construction component 16 and have a plurality of male snaps 32 thereon. In the view shown, the female snap 18 and the male snap 32 face the viewer of the image for ease of viewing, however, it should be understood that the wall panel 70 with the male snap 32 would have to be sequentially rotated by an amount to allow the male snap 32 to be inserted through the hole 24 in the female snap 18. The female snap 18 extends inwardly in the snap cavity 72. The male snap 32 extends from one face of the wall panel 70 and is inserted through the aperture 24 into the cavity 72 at which point the wall panel 70 can be lowered to form a clamping engagement between the female and

male snaps

18 and 32.

The

wall panels

68 and 70 may have a similar construction to the top panels described above. The

wall panels

68 and 70 may each include a core panel 74 of EPS surrounded by a frame 76, the frame 76 being formed of a metal channel member. MgO slabs 78 may be provided on both faces of the

wall panels

68 and 70. The panel can be made using different construction methods and materials, including cross-laminated panels and conventional stub construction panel technology.

A system for joining wall panels together is shown in fig. 12. The first wall panel is shown at 80 and the second wall panel is shown at 82. The

wall panels

80 and 82 can be joined together in a manner that allows them to be securely fastened together. In this way, the wall panels may be erected edge to edge, and thus the building may have a height greater than the height of one wall panel. As can be seen, each wall panel has a core panel 74 of EPS, with a frame 76 and an outer layer 78 of MgO board on either side, which gives the wall a finished appearance. Note that the panels can be made using different construction methods and materials, including cross-laminated panels and conventional stub construction panel technology. Each

wall panel

80, 82 has a support plate 84. The support plate 84 on the first wall panel 80 may be referred to as a first support plate 84 a. The support plate 84 in the second wall panel 82 may be referred to as a second support plate 84 b. The first support plate 84a has a clamping surface 86 and the second support plate 84b has a second clamping surface 88. A threaded member 90 (e.g., a threaded rod) passes from a first end cavity 92 in the first wall panel 80, through the first support plate 84a, through the second wall panel 82, and through the second support plate 84 b. The first end (shown at 94) abuts the first clamping surface 86 via a rivet nut 96 or any other suitable means to prevent the first end 94 from passing through the support plate 84 a.

The second end shown at 98 of the threaded member 90 has a nut 100 thereon, which nut 100 can be tightened down against the second clamping surface 88. By tightening the nut down, the second wall panel 82 is tightly clamped against the edge of the first wall panel 80. Male and female type snaps (not shown in fig. 12) may also be used to help join the two wall panels in a similar manner to their use in the wall panel shown in fig. 11. Thus, the tighter the nut 100 is tightened, the more the

snaps

18 and 32 engage each other.

Also shown in fig. 12 is a spacer 101 arranged to cover the interface between two

adjacent wall panels

80 and 82. The spacer 101 may also seal the interface between the

wall panels

80 and 82 from the introduction of moisture or other contaminants that may be harmful thereto. The spacers 101 also serve to allow some tolerance in the distance between the outer layers 78 of

adjacent wall panels

80 and 82 from each other so that the interface is not exposed even if the

wall panels

80 and 82 do not abut as closely as desired.

Referring to fig. 13, it is shown how the first wall panel 80 is coupled to the bottom. In fig. 13, the threaded member 90 extends upwardly through a support plate (in this case, the support plate is the upper wall 104 of a rectangular hollow cross-section beam shown at 106). The nut 96 prevents the first end 94 of the threaded member 90 from passing through the upper wall 104. The screw member 90 passes through the support plate and into the wall panel 80, passes through the wall panel 80, and as shown in fig. 12, passes through the support plate 84b, and is clamped down in the support plate 84b by the nut 100.

Referring back to fig. 13, a wall end member 108 may be provided on a lower edge of the wall panel 80 for engagement with a bottom surface, shown at 110, on which the wall panel 80 is mounted. The wall end member 108 may include a wall end member housing 112 and a wall end member core member 114.

An advantageous bottom support system is shown at 150 in fig. 13 for supporting the bottom panel 115. The bottom support system 150 includes the cross member 106 and the bottom support member 116 described above. The cross member 106 extends horizontally and has the top wall 104, bottom wall 118 and side walls 120 described above. In this embodiment, the cross beam is a rectangular hollow section beam and thus the side wall 120 is a first side wall and the cross beam 106 further comprises a second side wall 122. The cross beam 106 also has an interior 124, the interior 124 being at least partially defined by the top wall 104, the bottom wall 118, and the side wall 120 (and, in this example, the second side wall 122).

The side wall 120 has a plurality of bottom support through slots shown at 126 therethrough. The bottom support through slots 126 are horizontally spaced apart from each other. The cross beam 106 is more clearly shown in fig. 13. The bottom support member 116 may be generally L-shaped and include a vertical portion 128 extending upwardly from the slot in the interior and proximate the side wall 120 and a horizontal portion 130, the horizontal portion 130 extending outwardly through the slot 126 to support the bottom panel 115. One embodiment of the cross beam 106 and bottom support member 116 is shown in fig. 14. As can be seen, the bottom support member 116 is provided with a cut-out 132 in the vertical portion 128 and the cut-out 132 extends partially in the horizontal portion 130 to allow it to fit in the plurality of slots 126. Alternatively, a separate bottom support member 116 may be provided. By mounting the bottom support member 116 to the cross beam 106 in this manner, the bottom support member 116 is supported by the cross beam 106 but separated from the cross beam 106. No welding and mechanical fasteners are required to connect the bottom support member 116 to the cross beam 106. This provides a more predictable joint and requires relatively less time to install than joints that rely on welding.

The bottom panel 115 may be aerated concrete, such as the trade name owned by the Xella group, Germany

With aerated concrete provided, the bottom panel 115 can be supported on the horizontal portion 130 of the bottom support member 116 and can be fastened thereto using mechanical fasteners 132 (e.g., concrete screws) such that the bottom panel 115 abuts the side walls 120 of the cross beam 106. This will hold the bottom support member 116 snugly against the inside face of the side wall 120.

The "core panels" or "panels" in the above-mentioned applications can be manufactured using a variety of different construction methods and materials known to those of ordinary skill in the art, including cross-lamination, wood, stud wall, and conventional construction panel technologies.

Those skilled in the art will appreciate that many more alternative embodiments and modifications are possible, and that the above examples are merely illustrative of one or more embodiments. Accordingly, the scope is to be limited only by the following claims.

Claims

1. A joining system for connecting a first building construction element and a second building construction element, the joining system comprising:

a female snap connectable to a first building construction component and comprising a first female snap receiving surface and a second female snap receiving surface, wherein the first and second female snap receiving surfaces face away from each other and are adjacent to a male snap through hole defining a hole axis;

a male snap connectable to a second building construction component and comprising a first male snap clamping surface and a second male snap clamping surface, wherein the first and second male snap clamping surfaces face each other, wherein a portion of the male snap is insertable through the male snap through-hole and is movable in a first transverse direction to clamp the female snap; and

a locking device comprising a first locking structure on the female buckle and a second locking structure on the male buckle, wherein the first locking structure is engageable with the second locking structure to allow movement of the male buckle in a first lateral direction to increase a clamping force of the male buckle on the female buckle and inhibit movement of the male buckle in a second lateral direction opposite the first lateral direction;

the female snap includes a laterally extending female snap base and a female snap tab extending perpendicular to the female snap base, and wherein the male snap includes a laterally extending male snap base and a male snap tab perpendicular to the male snap base.

2. The bonding system of claim 1, wherein the first locking structure comprises a plurality of female-type snap-fit teeth on the first female-type snap-fit receiving surface, and the second locking structure comprises a plurality of male-type snap-fit teeth on the first male-type snap-fit clamping surface, wherein the female-type snap-fit teeth and the male-type snap-fit teeth are capable of interdigitating with one another in an axial or transverse plane.

3. The binding system of claim 1, wherein the first locking structure comprises a pawl on the female snap, wherein the second locking structure comprises a plurality of male snap teeth, wherein the locking device further comprises a pawl biasing member that urges the pawl toward engagement with the male snap teeth.

4. The bonding system of claim 1, wherein the first female-type snap-receiving surface is located on a female-type snap tab and the second female-type snap-receiving surface is located on a female-type snap tab, and wherein the first male-type snap-clamping surface is located on a male-type snap tab and the second male-type snap-clamping surface is located on a male-type snap tab.