DE202024105463U1 - System and construction module with aligned wood fibers - Google Patents

Abstract

A structural composite building module comprising a top plate connected to a structural base made from a composite material containing aligned wood fibers and a binder.

Description

TECHNICAL FIELD

This disclosure relates to the fields of construction, architecture and engineering, and more particularly to a structural composite building module. This disclosure also relates to a load-bearing structural system and a modular building system.

BACKGROUND

In the field of construction and manufacturing of load-bearing structural elements that can withstand mechanical stress, such as walls, slabs or floors, reducing component weight and material quantity have become priorities for both economic and sustainability reasons.

Various industries, especially construction and transportation, are using new technologies and lightweight composites to achieve the required structural properties and meet their environmental goals, such as reducing CO2 emissions, raw material use and energy consumption. In this context, composites and wood are becoming increasingly popular due to their high mechanical strength, suitability for digital manufacturing and low environmental impact.

The construction sector is currently facing two fundamental challenges: 1) significantly reducing its environmental impact and 2) improving its productivity. Globally, the construction sector is responsible for 40% of CO2 emissions and 40% of raw material consumption. This is due to the massive use of non-renewable materials with high CO2 emissions, such as concrete and steel, as well as their inefficient use. On the other hand, productivity in construction has been stagnating for decades due to the low level of prefabrication and the lack of integration in its production chain.

In this context, wood has re-emerged as a construction material of great relevance for the future due to its renewable nature, suitability for prefabrication and its ability to sequester CO2. However, climate change is threatening some of the forest species most commonly used in construction, heralding a future of scarce and expensive wood. In addition, the predominantly structural wood technologies are inefficient in using forest resources: CLT (Cross Laminated Timber) uses only 20-40% of the tree and LVL (Laminated Veneer Lumber) uses less than 70% and requires large, well-shaped trees. All this presents a scenario of rising wood prices and the prospect of shortages that threaten the transition to sustainable construction ( Pramreiter et al. 2023 ).

In the professional world, various structural timber building elements - or structural elements with wooden parts - are known for use in construction as walls, floors or ceilings, among others. In the construction industry, layered solid wood panels consisting of several layers arranged flat on top of each other in a cross-orientation are known as cross-laminated timber (CLT) panels and are mainly used in wall, roof or ceiling constructions.

Other lighter solutions for wooden floors, ceilings or walls use "ribs" or beams to separate the top and bottom boards. Some of these lightweight wooden panels are made from a longitudinal grid, where each beam must be individually placed, glued and/or screwed to form a so-called "cassette" panel (such as Metsä's Kerto-Ripa or Bestwood Schneider's CLT Box). This process is slow, laborious and costly, requires a specialized facility to manufacture such products and results in elements that have structural rigidity in only one direction.

The patent application WO2011028124A1 presents a sandwich-type floor or roof element called a floor spacer or "hollow wood layer", which is a prefabricated panel or panel-like element for assembly over long spans. The element consists of two panels and spacer units between them and has been designed with a curvature of approximately 1 mm along its longitudinal direction. The bottom panel has an adjustable curvature to adapt to the desired span and load. The spacer units are placed in rows along the length of the member, with the distance between rows varying from 0.1 to 1.5 meters. Made of wood or metal, these units have flat, parallel surfaces facing the panels.

Similarly, the patent DE202007001771U1 a load-bearing wooden structure open, designed for use as walls, ceilings, for large spans and similar applications. It consists of upper and lower multi-layer panels made of solid wood, with vertical panels at the ends and additional panels in the middle, so that hollow boxes are formed. These hollow boxes are insulated and are connected by gluing or vacuum pressing and require several pressing steps and complex machines that can press in both directions.

The patent DE202018101347U1 represents a cross-laminated wood element of the CLT type, consisting of several layers, including longitudinal and transverse layers of wood panels. It also includes a cover panel made of pressed wood fibers with a density of more than 600 kg/m ³ , which is bonded to the other layers by an adhesive.

Regarding the composite materials available for the manufacture of strong and lightweight objects, carbon or glass fiber reinforced plastics are widely used in some industries. Although such materials can be strong and lightweight, their structural performance is inadequate for the construction industry, they are not sustainable due to the high CO2 emissions generated during their manufacture, their non-renewable origin and their low recyclability. In addition, their high cost limits their use at the scale and volume required in the construction industry.

On the other hand, sustainable composites based on plant fibres such as jute, linseed and hemp are available. Although suitable for lightweight structures, they contain high levels of resins (over 40%), tend to have unstable mechanical properties and have poor fire resistance, which present similar limitations to synthetic fibres such as carbon and glass fibre in terms of productivity and cost. In addition, plant fibres such as linseed are annual crops that are extremely sensitive to drought, making their availability in the quantities required for construction questionable in the face of climate change.

Well-known state-of-the-art lightweight timber structural products currently available on the market - especially for flooring or panel applications - such as CLT-Box (Bestwood Schneider) or Kerto Ripa (Metsa), use "cassette" configurations, namely panel and beam assemblies in prism shape and with orthogonal grain orientation, forming a sort of box with parallel internal longitudinal ribs along the direction of the element's span. Although this configuration can be successfully used for structural elements, it has a number of disadvantages. The first is that they have low stiffness in the direction opposite to the element's span. This limits the maximum dimensions of the element and its support conditions. Larger elements in construction allow reducing assembly area schedules and costs.

SUMMARY

An object of the present disclosure is to provide a structural composite building module, a load-bearing structural system and a modular building system that can solve one or more of the above-mentioned problems and other problems known in the prior art. The object is achieved by the features of the respective independent claims. Further embodiments are defined in the respective dependent claims.

According to a first aspect, there is provided a structural composite building module, said module comprising a top plate connected to a structural base made of a composite material containing aligned wood fibers and binders.

• eine Basis, bestehend aus mindestens einer gewellten Hülle, umfassend ausgerichtete Holzfasern und Bindemittel, die auf ihrer Oberseite mit der Unterseite einer oberen Platte verbunden ist;
• eine obere Platte, die sich im oberen Bereich des Systems befindet, die die Last aufnimmt und eine Platte einer Art ist, die ausgewählt ist aus der Gruppe bestehend aus Sperrholz, Massivholz, OSB, CLT, Spanplatte, Faserzementplatte, Betonplatte, WPC-Platte, einer Verbundplatte, einer Polymerplatte, einer Biopolymerplatte, einer Polymerverbundplatte und einer Platte der gleichen Materialart wie das Material der Basis; und
• Verbindungselemente, die die obere Platte mit der Basis verbinden; wobei mindestens eine der Seiten des Umfangs des Systems auf einem anderen Strukturelement aufliegt und/oder an diesem befestigt ist und die obere Platte, wenn sie eine Last aufnimmt, die von dieser besagten Last abgeleiteten Kräfte auf die mindestens eine gewellte Hülle überträgt, deren Gestaltung und die Ausrichtung ihrer Fasern absichtlich durch Parameter bestimmt werden, die mittels digitaler oder analoger Optimierungswerkzeuge erzeugt werden, um die besagten Kräfte aufzunehmen und sie hauptsächlich durch den Membraneffekt im gesamten System zu verteilen, so dass alle Teile des Systems zusammen mit der Tätigkeit der Verbindungselemente zusammenwirken und die Tragfähigkeit des Systems maximiert wird.

According to a second aspect, a load-bearing structural system is provided, said system comprising:

• a base consisting of at least one corrugated shell comprising aligned wood fibers and binder bonded on its upper surface to the underside of a top plate;
• a top plate located in the upper part of the system, which bears the load and is a plate of a type selected from the group consisting of plywood, solid wood, OSB, CLT, particle board, fibre cement board, concrete board, WPC board, a composite board, a polymer board, a biopolymer board, a polymer composite board and a plate of the same type of material as the material of the base; and
• connecting elements connecting the upper plate to the base; at least one of the sides of the perimeter of the system rests on and/or is fixed to another structural element, and the upper plate, when it receives a load, transmits the forces derived from said load to the at least one corrugated sheath, the configuration and the orientation of its fibers of which are deliberately determined by parameters generated by means of digital or analog optimization tools, in order to absorb said forces and distribute them throughout the system, mainly through the membrane effect, so that all parts of the system cooperate with the action of the connecting elements and the load-bearing capacity of the system is maximized.

• eine Vielzahl von strukturellen Verbundbaumodulen nach dem ersten Aspekt; und
• Verbindungsmittel;
• wobei die strukturellen Verbundbaumodule durch die Verbindungsmittel strukturell verbunden sind.

According to a third aspect, a modular construction system is provided, said system comprising:

• a plurality of structural composite modules according to the first aspect; and
• connecting means;
• wherein the structural composite modules are structurally connected by the connecting means.

One objective of this disclosure is to provide lightweight and sustainable wood-based building elements with dimensions and load-bearing capacity to the extent required in the construction and transport sectors.

The module according to the present disclosure was designed using optimization tools, is load-bearing, has a generally flat shape, comprises interacting parts, and can serve as a wall, slab, ceiling, floor, bridge, beam, column, door, and/or inclined plane, among others. This building module can comprise three main layers (top plate - core - bottom plate) or two main layers (top plate - base). The core or base is a layer made of a compression-molded composite material containing binder and individual wood fibers (e.g., wood strands or flakes) deliberately aligned according to a design generated through the use of optimization tools, preferably in the form of a corrugated shell that is bonded to the other plate or plates of the other layer or layers, forming a system of parts that interact to carry loads with small amounts of material, resulting in a structural composite building module with low weight and high performance. This type of building module is useful for the construction and assembly of large structures, e.g., a building. E.g. buildings, houses, bridges, aircraft and ships, and offers an alternative that is stronger, more durable, easier to install and more environmentally friendly than existing solutions.

The module according to the present disclosure consists of a new type of prefabricated lightweight structural building modules that have bidirectional stiffness and strength and can be used as a slab, beam or roof with small or large spans or as a wall, column or other building elements and are useful for the construction and assembly of large structures such as buildings, houses, bridges, aircraft and ships, offering greater strength, durability and environmental compatibility than existing solutions. In addition, the modular nature of the prefabricated lightweight structural building module presented here simplifies its installation, thus enabling faster and more efficient construction processes.

The building module presented here can comprise two main layers (top plate and base) or three main layers (top plate, core and bottom plate). The core or base is a layer of a compression-molded composite material containing binder and individual wood fibers (e.g. wood strands or flakes) that are deliberately aligned according to a design generated with optimization tools and are preferably shaped like a corrugated shell. Said core or base may comprise more than one corrugated shell or sub-layers and, when connected to the other panel layer(s) of the module, results in a system of cooperating parts, wherein at least one side of the module perimeter is supported by and/or fixed to another structural element and the upper panel, when it receives a load, transmits the forces derived from said load to the core or base, the design of which has been optimized to absorb such forces and distribute them throughout the system, mainly using the membrane effect, so that each part, together with the action of the connecting means, cooperates in such a way as to maximize the load-bearing capacity of the system, while using the least possible amount of material, achieving lightweight structural building modules capable of spanning large distances between supports, generally more than 6 meters.

As mentioned above, the module may comprise a core or base layer of a compression molded composite material containing wood fibers (e.g. wood strands or flakes) and binders, bonded to a top plate and in some embodiments also to a bottom plate, which may be CLT, LVL or other types of panels. By using molded wood fibers, strands, flakes or the like, the module is a very resource efficient structural solution, as up to 95% of the tree is utilized ( Shmulsky and Jones 2010 ).

From a materials science perspective, a composite material is a material formed from two or more components such that the properties of the final material are more powerful and/or advantageous than those of the individual components. Similarly, composite structures are structures that comprise a combination of two or more elements of the same or different materials that are bonded together in such a way that they work together to combine the properties of each individual component to form a structural Take advantage of the system as a whole. Composite structures and composite materials can be designed to achieve combinations with exceptional performance in terms of stiffness, load-bearing capacity, durability under extreme temperature conditions, corrosion resistance, hardness, flexibility, electrical conductivity and other properties.

Using shape design, optimization and fiber architecture technologies, as well as production technologies that combine developments in materials science and additive manufacturing, the present building module brings the logic of advanced composites used in the aerospace, transportation and mobility industries to the world of wood and construction, and is strong enough to be a sustainable alternative to materials such as steel, aluminum or fiber-reinforced plastics in the transportation and mobility industries and to materials such as steel and concrete in buildings, helping to solve three of the main problems in construction: sustainability, industrial productivity and structural performance.

Another objective is to provide an efficient and more cost-effective solution to replace materials that are less efficient in using forest resources and/or cause increased CO2 emissions, thus contributing to reducing the high carbon dioxide (CO2) emissions generated by various industries, with a particular focus on the construction sector.

By significantly reducing the amount of material and the weight of panels, floors, roofs and/or walls, the consumption of trees is significantly reduced and the entire building structure becomes lighter, which has a positive impact on the reduction of CO2 emissions and the cost structure of the entire building, further reducing assembly costs as well as the costs and CO2 emissions related to the transport of the construction elements for said building.

The present module and systems offer several advantages over the state of the art in terms of lightweight structures for sustainable construction. The first advantage concerns material efficiency and its impact on the sustainability of the product. Most structural products for sustainable construction are currently made from wood-based materials. Glulam, CLT and LVL are the most commonly used materials. Glulam and CLT use sawn timber as the main material. The efficiency of sawn timber for these structures is very low: between 20 and 40% of the tree is used for structural purposes. The situation is similar for LVL, which requires large, well-shaped trees and uses up to 70% of them. The material used for the base or core of the module, and responsible for its material strength properties, is a composite material consisting mainly of wood flakes or fibres. This form of wood used is very efficient for the construction of structures because, as mentioned above, it achieves a use of up to 95% of forest resources. In addition, small and poorly shaped trees can be used, which are generally discarded for structural purposes.

This multidimensional material efficiency results in a reduction in the number of trees needed to build building structures. It is estimated that such a structure can reduce the number of trees needed to a quarter compared to a CLT structure with equivalent mechanical properties. This is environmentally friendly as it allows an increase in the number of buildings built from wood without increasing the pressure on forests and plantations. In addition, the proposed product can be made from different tree species and different fiber formats or combinations thereof, which allows the product to be adapted to the resource availability of the production environment.

In addition, the use of this material input format is not only more efficient in the use of forest resources, but also allows for increased efficiency in the products made from them. Flakes and fibers can enable the formation of three-dimensional "free-form" elements and control of the orientation and location of the fibers.

It is known in engineering that the greatest structural efficiency, as in nature, is achieved with complex, non-prismatic shapes, since stresses travel along non-prismatic paths and complex shapes allow material to be used only where it is needed. Similarly, wood is an anisotropic material, meaning that it is stronger in one direction than in the direction perpendicular to it. As a general rule, this ratio is 10 to 1. Therefore, a material architecture whose fibers can be aligned in the direction of the load provides the best ratio of material input to mechanical performance. Since the present module can be formed in either direction depending on the requirements of the specific case, it can provide bidirectional stiffness. Furthermore, due to its optimized shape and fiber orientation, it can achieve an optimal stiffness ratio for both major directions.

In addition, the present module allows the manufacture of a lightweight, high-performance construction module with few elements and is easy to assemble. Unlike lightweight cassette elements, which include several elements to achieve a strong configuration, the present module - in its simplest version - can be manufactured with two elements: a plate and a corrugated base. This also provides advantages in terms of assembly times.

Another interesting aspect of some of the preferred embodiments is that, since they are partially hollow structures, they allow the inclusion of thermal and acoustic insulation and fire protection elements, as well as the insertion of cable ducts and pipes through them, without having to modify the structure. This is relevant in terms of costs and CO2 emissions, as the floor packages can be made thinner, thus saving additional material in the form of insulation layers, cable ducts and pipes, and maximizing the usable area and/or the number of floors of the entire building.

The design of the structural base or core is based on the principle of a corrugated shell that allows shear forces to be transferred between the panels through the membrane effect, meaning that stresses are transferred across the material surface, with the shape acting as the main performance driver. This results in efficient load transfer with minimal material usage, while creating a rigid base or core in two directions.

The outer panel(s) provide protection and contribute to the structural integrity of the composite module, while the base or core mainly provides stiffness and spacing between the outer panels, improving the strength-to-weight ratio of the structure and aiming to minimize buckling and bending of the shell (base or core).

The top and bottom panels can be any type of commercially available wood panel, such as CLT, LVL, OSB, plywood, panels made of other materials, or panels made of a composite material similar to that of the core or base material.

Further features and advantages will become apparent from the detailed description provided after the brief description of the drawings.

SHORT DESCRIPTION OF THE DRAWINGS

• 1A: Explosionsdarstellung in diagonaler Perspektive einer Ausführungsform des Baumoduls, umfassend zwei Schichten, zusammen mit einer vergrößerten Nahaufnahme der ausgerichteten Holzfasern aus dem Verbundwerkstoff der Basis.
• 1B: Diagonale perspektivische Ansicht derselben Ausführungsform des in 1A abgebildeten Baumoduls, wobei die Basis unter der oberen Platte durch gestrichelte Linien dargestellt ist.
• 2: Bild vom 3D-Modell des Entwurfs einer gewellten Hülle, die nach einem digitalen Optimierungsprozess als Basis oder Kern des Baumoduls verwendet wird.
• 3A: Explosionsdarstellung in diagonaler Perspektive einer weiteren Ausführungsform des Baumoduls, umfassend zwei Schichten, zusammen mit einer vergrößerten Nahaufnahme der ausgerichteten Holzfasern aus dem Verbundwerkstoff der Basis.
• 3B: Diagonale perspektivische Ansicht derselben Ausführungsform des in 3A abgebildeten Baumoduls.
• 3C: Seitliche Aufrissansicht derselben Ausführungsform des in den 3A und 3B abgebildeten Baumoduls.
• 3D: Vordere Aufrissansicht derselben Ausführungsform des in den 3A, 3B und 3C abgebildeten Baumoduls.
• 4: Diagonale perspektivische Ansicht einer weiteren Ausführungsform des Baumoduls von unten, umfassend zwei Schichten, zusammen mit einer vergrößerten Nahaufnahme einer Vielzahl von Teilschichten von ausgerichteten Fasern und Bindemittel, die von der Basis umfasst werden, und einer vergrößerten Nahaufnahme ihrer ausgerichteten Fasern.
• 5A: Diagonale perspektivische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend zwei Schichten.
• 5B: Diagonale perspektivische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten.
• 6: Eine Reihe von Beispielen für einige der verschiedenen Arten von regelmäßigen Wellen, die Teil der Form der Wellung oder der Wellungen der gewellten Hülle sein können, die die Basis oder den Kern des Baumoduls bildet.
• 7: Eine Reihe von Beispielen für einige der verschiedenen Arten von unregelmäßigen Wellen, die Teil der Form der Wellung oder der Wellungen der gewellten Hülle sein können, die die Basis oder den Kern des Baumoduls bildet.
• 8A: Isometrische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend zwei Schichten.
• 8B: Isometrische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend dieselben Elemente wie die in 8A abgebildete Ausführungsform und ferner umfassend eine dritte Schicht.
• 9A: Isometrische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend zwei Schichten.
• 9B: Isometrische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend dieselben Elemente wie die in 9A abgebildete Ausführungsform und ferner umfassend eine dritte Schicht.
• 10: Perspektivische Vorderansicht einer weiteren Ausführungsform des Baumoduls, umfassend zwei Schichten.
• 11: Perspektivische Vorderansicht einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten, mit seinen Verbindungsmitteln zum Verbinden mit einer Betonsäule, ebenfalls in der vorliegenden Figur abgebildet.
• 12: Perspektivische Vorderansicht einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten.
• 13: Perspektivische Vorderansicht einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten.
• 14: Vordere perspektivische Explosionsdarstellung einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten.
• 15: Vordere perspektivische Explosionsdarstellung einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten.
• 16A: Explosionsdarstellung in diagonaler Perspektive einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten und zwei seitliche Platten, zusammen mit drei vergrößerten Nahaufnahmen der ausgerichteten Holzfasern des Verbundwerkstoffs des Kerns und der oberen und unteren Platten.
• 16B: Diagonale perspektivische Ansicht derselben Ausführungsform des in
• 16A abgebildeten Baumoduls.
• 17A: Isometrische Explosionsdarstellung einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten und zwei seitliche Platten.
• 17B: Isometrische Ansicht derselben Ausführungsform des in 17A abgebildeten Baumoduls.
• 18A: Isometrische Explosionsdarstellung einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten und vier seitliche Platten.
• 18B: Isometrische Ansicht derselben Ausführungsform des in 18A abgebildeten Baumoduls.
• 19A: Isometrische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten und zwei seitliche Platten.
• 19B: Seitliche Aufrissansicht derselben Ausführungsform des in 19A abgebildeten Baumoduls.
• 20: Isometrische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten.
• 21A: Explosionsdarstellung in Frontalperspektive einer weiteren Ausführungsform des Baumoduls, umfassend zwei Schichten.
• 21B: Perspektivische Vorderansicht derselben Ausführungsform des in 21A abgebildeten Baumoduls, die zeigt, dass sich die obere Platte in Pfeilrichtung bewegt.
• 21C: Perspektivische Vorderansicht derselben Ausführungsform des in den
• 21A und 21B abgebildeten Baumoduls.
• 22A: Diagonale perspektivische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend zwei Schichten.
• 22B: Diagonale perspektivische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend dieselben Elemente wie die in 22A abgebildete Ausführungsform, ferner umfassend eine untere Platte.
• 23: Isometrische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten.
• 24: Isometrische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten und zwei seitliche Platten.
• 25: Isometrische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend zwei Schichten.
• 26: Isometrische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten.
• 27: Isometrische Ansicht einer weiteren Ausführungsform des Baumoduls, umfassend drei Schichten.
• 28: Diagonale perspektivische Ansicht einer weiteren Ausführungsform des Baumoduls von unten, umfassend drei Schichten.
• 29: Isometrische Ansicht einer Ausführungsform des Bausystems, in der drei gleiche Baumodule zu sehen sind, umfassend drei Schichten.
• 30A: Trimetrische Explosionsdarstellung einer weiteren Ausführungsform des Baumoduls, umfassend zwei Schichten.
• 30B: Seitliche Aufrissansicht derselben Ausführungsform des in 30A abgebildeten Baumoduls.
• 30C: Trimetrische Ansicht einer weiteren Ausführungsform des Bausystems, wobei es zwei Baumodule gibt, die gleich den in den 30A und 30B abgebildeten sind, verbunden mit einem Baumodul der gleichen Art wie die in 29 abgebildeten, zusammen mit einer vergrößerten Nahaufnahme ihrer Verbindung.
• 31A: Isometrische Ansicht von zwei gleichen und verbundenen Baumodulen nach einer Ausführungsform, die drei Schichten und Verbindungsmittel vom Nut-und-Feder-Typ zum Verbinden mit anderen gleichen oder ähnlichen Baumodulen umfasst, zusammen mit einer vergrößerten Nahaufnahme der besagten Verbindungsmittel.
• 31B: Vordere Aufrissansicht von zwei Baumodulen derselben Ausführungsform des in 31A abgebildeten Baumoduls, getrennt durch einen weißen Pfeil, der auf die Bewegung eines Baumoduls in Richtung des anderen hinweist.
• 32A: Vordere Aufrissansicht einer Ausführungsform des tragenden Struktursystems, bestehend aus zwei Schichten; obere Platte und Basis.
• 32B: Seitliche Aufrissansicht derselben Ausführungsform des in 32A abgebildeten tragenden Struktursystems.
• 32C: Vordere Aufrissansicht einer Ausführungsform des tragenden Struktursystems, bestehend aus drei Schichten; obere Platte, Kern und untere Platte.
• 32D: Seitliche Aufrissansicht derselben Ausführungsform des in 32C abgebildeten tragenden Struktursystems.
• 33: Graustufen-schattierte diagonale perspektivische Ansicht einer Art von gewellter Hülle, gezeigt in den in den 1A, 1B, 16A und 16B abgebildeten Ausführungsformen.
• 34: Graustufen-schattierte diagonale perspektivische Ansicht einer weiteren Art von gewellter Hülle.
• 35: Graustufen-schattierte diagonale perspektivische Ansicht einer weiteren Art von gewellter Hülle.
• 36: Graustufen-schattierte diagonale perspektivische Ansicht einer weiteren Art von gewellter Hülle.

A brief description of the drawings is provided, followed by a detailed description of the drawings to explain some of the preferred embodiments.

• 1A : Exploded view in diagonal perspective of an embodiment of the building module comprising two layers, together with an enlarged close-up of the aligned wood fibers of the composite base.
• 1B : Diagonal perspective view of the same embodiment of the 1A illustrated building module, with the base under the upper plate shown by dashed lines.
• 2 : Image of the 3D model of the design of a corrugated shell, which will be used as the base or core of the building module after a digital optimization process.
• 3A : Exploded view in diagonal perspective of another embodiment of the building module comprising two layers, together with an enlarged close-up of the aligned wood fibers of the composite base.
• 3B : Diagonal perspective view of the same embodiment of the 3A construction module shown.
• 3C : Side elevation view of the same embodiment of the 3A and 3B construction module shown.
• 3D : Front elevation view of the same embodiment of the 3A , 3B and 3C construction module shown.
• 4 : Diagonal perspective view from below of another embodiment of the building module comprising two layers, together with an enlarged close-up of a plurality of sublayers of aligned fibers and binder comprised by the base and an enlarged close-up of their aligned fibers.
• 5A : Diagonal perspective view of another embodiment of the building module comprising two layers.
• 5B : Diagonal perspective view of another embodiment of the building module comprising three layers.
• 6 : A set of examples of some of the different types of regular waves that form part of the shape of the corrugation or wave elements of the corrugated shell that forms the base or core of the building module.
• 7 : A set of examples of some of the different types of irregular corrugations that may form part of the shape of the corrugation or corrugations of the corrugated shell that forms the base or core of the building module.
• 8A : Isometric view of another embodiment of the building module comprising two layers.
• 8B : Isometric view of another embodiment of the construction module, comprising the same elements as in 8A illustrated embodiment and further comprising a third layer.
• 9A : Isometric view of another embodiment of the building module comprising two layers.
• 9B : Isometric view of another embodiment of the construction module, comprising the same elements as in 9A illustrated embodiment and further comprising a third layer.
• 10 : Perspective front view of another embodiment of the building module comprising two layers.
• 11 : Perspective front view of another embodiment of the building module comprising three layers, with its connecting means for connecting to a concrete column, also shown in the present figure.
• 12 : Perspective front view of another embodiment of the building module comprising three layers.
• 13 : Perspective front view of another embodiment of the building module comprising three layers.
• 14 : Front perspective exploded view of another embodiment of the building module comprising three layers.
• 15 : Front perspective exploded view of another embodiment of the building module comprising three layers.
• 16A : Exploded view in diagonal perspective of another embodiment of the building module comprising three layers and two side panels, together with three enlarged close-ups of the aligned wood fibers of the composite material of the core and the top and bottom panels.
• 16B : Diagonal perspective view of the same embodiment of the
• 16A construction module shown.
• 17A : Isometric exploded view of another embodiment of the building module, comprising three layers and two side panels.
• 17B : Isometric view of the same embodiment of the 17A construction module shown.
• 18A : Isometric exploded view of another embodiment of the building module, comprising three layers and four side panels.
• 18B : Isometric view of the same embodiment of the 18A construction module shown.
• 19A : Isometric view of another embodiment of the building module, comprising three layers and two side panels.
• 19B : Side elevation view of the same embodiment of the 19A construction module shown.
• 20 : Isometric view of another embodiment of the building module comprising three layers.
• 21A : Exploded view in frontal perspective of another embodiment of the building module, comprising two layers.
• 21B : Perspective front view of the same embodiment of the 21A shown construction module, showing that the upper plate moves in the direction of the arrow.
• 21C : Perspective front view of the same embodiment of the
• 21A and 21B construction module shown.
• 22A : Diagonal perspective view of another embodiment of the building module comprising two layers.
• 22B : Diagonal perspective view of another embodiment of the building module comprising the same elements as those in 22A illustrated embodiment, further comprising a bottom plate.
• 23 : Isometric view of another embodiment of the building module comprising three layers.
• 24 : Isometric view of another embodiment of the building module, comprising three layers and two side panels.
• 25 : Isometric view of another embodiment of the building module comprising two layers.
• 26 : Isometric view of another embodiment of the building module comprising three layers.
• 27 : Isometric view of another embodiment of the building module comprising three layers.
• 28 : Diagonal perspective view of another embodiment of the building module from below, comprising three layers.
• 29 : Isometric view of an embodiment of the construction system, showing three identical construction modules comprising three layers.
• 30A : Trimetric exploded view of another embodiment of the building module, comprising two layers.
• 30B : Side elevation view of the same embodiment of the 30A construction module shown.
• 30C : Trimetric view of another embodiment of the construction system, where there are two construction modules, which are identical to those shown in the 30A and 30B shown, connected to a construction module of the same type as those in 29 pictured, along with a magnified close-up of their connection.
• 31A : Isometric view of two identical and connected building modules according to an embodiment comprising three layers and tongue-and-groove type connecting means for connecting to other identical or similar building modules, together with an enlarged close-up of said connecting means.
• 31B : Front elevation view of two modules of the same embodiment of the 31A shown building module, separated by a white arrow indicating the movement of one building module towards the other.
• 32A : Front elevation view of an embodiment of the load-bearing structural system consisting of two layers; top plate and base.
• 32B : Side elevation view of the same embodiment of the 32A load-bearing structural system shown.
• 32C : Front elevation view of an embodiment of the load-bearing structural system consisting of three layers; top plate, core and bottom plate.
• 32D : Side elevation view of the same embodiment of the 32C load-bearing structural system shown.
• 33 : Grayscale shaded diagonal perspective view of a type of corrugated shell shown in the 1A , 1B , 16A and 16B illustrated embodiments.
• 34 : Grayscale shaded diagonal perspective view of another type of corrugated shell.
• 35 : Grayscale shaded diagonal perspective view of another type of corrugated shell.
• 36 : Grayscale shaded diagonal perspective view of another type of corrugated shell.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

To facilitate understanding of this disclosure, we provide the following definitions, which should be understood only as an aid to explaining certain items described herein.

Sheath: The term "sheath" refers to a thin, curved three-dimensional structure with a small thickness compared to its other dimensions, and in which deformations are not large compared to the thickness. A major difference between a sheath structure and a plate structure is that the sheath structure has a curvature when unloaded, unlike the plate structure, which is flat. The membrane action in a sheath is primarily caused by in-plane forces (in-plane stresses), but secondary forces resulting from bending deformations may also occur. While a flat plate acts similarly to a beam with bending and shear stresses, sheaths are analogous to a cable that withstands loads through tensile stresses. The sheath must be resilient in both tension and compression.

In the context of our disclosure, the orientation of a corrugation or corrugations is mentioned, which refers to the longitudinal orientation of one or more corrugations along the surface of a particular body, mainly generally flat bodies, such as shells or plates.

• - „die allgemeine Anordnung der verschiedenen Teile von etwas, das hergestellt wird, wie ein Gebäude, ein Buch, eine Maschine usw.“
• - „die Kunst oder der Prozess, zu entscheiden, wie etwas aussehen, funktionieren usw. wird, indem man Pläne zeichnet, Computermodelle erstellt usw.“
• - „eine Zeichnung oder ein Plan, aus dem etwas hergestellt werden kann“
• - „ein Plan oder eine Absicht“

In the context of our disclosure, the term "draft" is used in a variety of contexts. In general, "draft" should be understood as one of the following definitions provided in the Oxford Learner's Dictionary:

• - "the general arrangement of the various parts of something being manufactured, such as a building, a book, a machine, etc."
• - "the art or process of deciding how something will look, function, etc. by drawing plans, making computer models, etc."
• - "a drawing or plan from which something can be made"
• - "a plan or intention"

• - Form
• - Größe
• - Kontur
• - Dicke
• - Dichte
• - Wellungen und allgemeine Oberflächenmerkmale
• - Position seiner Bestandteile, insbesondere Fasern und Bindemittel
• - Größe und Form seiner Bestandteile
• - Art, Menge und Position des Bindemittels oder der Bindemittel.

In particular, ‘design’ is used in the context of the basis or core of the module or system in question, taking into account, among others, the following specific variables and parameters of the design:

• - shape
• - Size
• - contour
• - thickness
• - density
• - Corrugations and general surface features
• - Position of its components, in particular fibres and binders
• - size and shape of its components
• - Type, quantity and position of the binder or binders.

Wave: In the context of this disclosure, the term “wave” refers to the path that represents the recognizable shape in a section of a wavy object, as defined by the “wave” in the previous paragraph.

Irregular wave: Refers to a wave with a shape that does not have regular periodicity, whose crests and/or troughs are not all the same and do not necessarily have the same distances and heights.

Composite wave: Refers to a wave that combines waves of different shapes and may or may not exhibit periodicity in such combinations.

Valley: In the context of this disclosure, the term “valley” refers to a low point or area between higher points or areas, the lowest part(s) of a wave or undulation.

Crest: In the context of this disclosure, the term “crest” refers to a high point or area between lower points or areas, the highest part(s) of a wave or undulation.

Mesh Rendering: The term "mesh" or "mesh rendering" refers to a type of visualization used in digital environments to represent 3D objects that uses a collection of points connected by lines, creating a visual and geometric approximation of the object being modeled.

Freeform, Freeform Element: In the context of this disclosure, the term “freeform” refers to designs, structures, or three-dimensional elements that are not constrained by regular or conventional geometric shapes and sometimes take on more fluid, organic, curvilinear, or irregular forms.

Bidirectional stiffness: In the context of this disclosure, the term “bidirectional stiffness” refers to the ability of a structural element, such as a plate, to resist small-deformation loads in two orthogonal directions.

Membrane effect: Refers to a phenomenon that occurs in thin structures, such as plates or shells, when they are subjected to loads that produce deformations predominantly in their plane, producing a distribution of the loads along the surface of the structure rather than over its entire volume. This results in bending and stresses at the surface rather than deformations throughout the structure.

Alignment: A line along which a point moves and which can be traversed in two opposite directions.

In the context of the present disclosure, the orientation of wood fibers, flakes, strands, and the like refers to their relative position with respect to the general orientation and position of the object to which they belong as a whole, as well as to the orientation of the wood fibers that make up all wood elements with respect to the general orientation and position of the object to which they belong as a whole and with respect to the individual flakes, strands, etc.

Direction: The point or location toward which something is moving, pointing, or facing.

Perimeter: The frame or outermost region of a surface, as distinguished from the central surface it contains.

Adjacent: In the context of the present disclosure, the term “adjacent” refers to a position of one object with respect to another where they are laterally touching or about to laterally touch, with both objects at the same or a similar level and not one above the other.

• OSB: Oriented Strand Board.
• CLT: Cross Laminated Timber.
• WPC: Wood Plastic Composite

Mirrored: In the context of this disclosure, the term “mirrored” is used in reference to mirrors and symmetry as a synonym for the term “specular,” where two things are related to each other in the same way that an object is related to its mirror image.

• OSB: Oriented Strand Board.
• CLT: Cross Laminated Timber.
• WPC: Wood Plastic Composite

As new configurations for elements, modules and building systems are introduced, there are several preferred embodiments that depend on the requirements of the part to be manufactured for each application.

It is also important to emphasize that, in the context of the present disclosure, all the various embodiments shown in the figures, as well as all possible embodiments that can be derived from the numerous possible combinations of structural, compositional, feature and design variables of the various components of the building modules, building systems and load-bearing structural systems claimed herein, are part of the modules and systems presented and those set out herein are only illustrative and didactic examples.

Similarly, it is important to stress that all the design features of the corrugated shells, the orientation of their aligned wood fibres and their joint relationship with the other constituent parts of the building modules, building systems and load-bearing structural systems claimed herein, as a product of optimisation using optimisation tools - whether digital or analogue - have engineering implications that lead to a reduction in the amount of material used and CO2 emissions in the manufacture of said building modules and load-bearing structural systems, while maximising their load-bearing capacity.

The way in which the multitude of layers of aligned fibers or flakes are structured is also variable and also depends on the requirements of the particular use case and the type of design. This means that determining the orientation and position of the fibers or flakes of an element can define an orientation in general and not too specific to the set of fibers, or it can define a deliberate and specific orientation and position for each of the fibers or flakes so that the mechanical performance of the part being manufactured, the amount of material used, or other variables specifically required are maximized.

It is important to note that in all figures containing one or more corrugated casings, each and every one of the various embodiments of the corrugated casings depicted - whether as the base of a two-layer structural member or as the core of a three-layer structural member - include some type or types of oriented wood fibers and one or more binders, even though some figures do not specifically depict or indicate such fibers on the surfaces of their respective corrugated casings or their respective numbers in the list of elements and numbers do not specifically mention this.

Similarly, all figures containing one or more corrugated shells bonded to a top and/or bottom plate are adhesive bonded unless the type of bond is specified.

REFERENCE NUMBERS:

2

Any two-layer embodiment of the building module or the load-bearing structural system

3

Any three-layer embodiment of the building module or the load-bearing structural system

4

3D model in "mesh" representation of a corrugated hull design in a three-dimensional Cartesian space coordinate system

100

upper plate

101

Upper CLT plate

102

Top plate made of 5-layer plywood

103

Upper composite panel comprising strand-like aligned wood fibers and binder

104

Upper fiber cement plate

110

Convex shaped upper plate

111

Curved top plate

112

Corrugated top plate

200

Corrugated casing made of wood fibers and binding agent

201

Corrugated casing made of veneer-like aligned wood fibers of uniform shape and size and binding agent

202

Corrugated casing made of aligned wood fibers, some fibers having the same shapes and sizes and others having different shapes and sizes, and binders

203

Corrugated casing made of chip-like aligned wood fibers and binding agent

204

Corrugated casing made of strand-like aligned wood fibers and binding agent

205

Corrugated casing made of aligned wood fibers, which are bamboo splinters, and binding agent

209

Corrugated shell with uneven thickness

210

Base comprising two different corrugated shells stacked on top of each other

211

Core comprising two identical corrugated shells stacked mirror-imaged on top of each other

212

Core comprising four adjacent identical corrugated shells arranged in a pattern of four corrugated shells with one corrugated shell

213

Core comprising six identical corrugated shells arranged in two mirrored stacked layers, each layer having three adjacent shells

214

Core comprising twenty-four adjacent corrugated shells of two different types arranged in an aligned pattern of six corrugated shells with four corrugated shells

215

A core comprising twenty-six adjacent corrugated shells of the same type and of two different sizes arranged in a non-aligned pattern of four corrugated shells in one direction and six and seven corrugated shells in the other direction

221

Corrugation or corrugations of a curved wave with medium frequency

222

Corrugation or corrugations of a low frequency curved wave

223

corrugation or corrugations of a trapezoidal wave

224

corrugation or corrugations of a square wave

225

corrugation or corrugations of a triangular wave

226

corrugation or corrugations of a sawtooth wave

227

Corrugation or corrugations of an irregular wave A

228

Corrugation or corrugations of an irregular wave B

229

Corrugation or corrugations of an irregular wave C

230

Corrugation or corrugations of an irregular wave D

231

Corrugation or corrugations of an irregular wave E

240

Corrugated shell with an overall convex shape

241

Corrugated case with an overall curved shape

241

Corrugated case with an overall wavy shape

300

lower plate

301

Lower plate made of 3-layer plywood

302

Lower plate with dotted lines marking the aligned pattern of twenty-four corrugated sheaths

303

Lower plate with dotted lines marking the misaligned pattern of the twenty-six corrugated covers

304

Bottom composite panel comprising strand-like aligned wood fibers and binder

305

Lower solid wood plate

310

Convex lower plate

311

Curved bottom plate

312

Corrugated bottom plate

320

Side plate perpendicular to the upper plate

321

Side plate diagonal to the upper plate

400

adhesive area

401

rivets

402

bolt

403

nuts

404

Spring-type connecting elements of a tongue and groove connection system for connecting elements of the building module

405

Groove-like connecting elements of a tongue and groove connection system for connecting elements of the building module

410

Cylindrical tongue and groove fasteners for connecting to other building elements

411

Spring-type fasteners of a tongue and groove connection system for connecting to other building elements

412

Groove-like connecting elements of a tongue and groove connection system for connecting to other building elements

413

Spring-like connecting elements of a tongue and groove connection system for connecting building modules to each other

414

Groove-like connecting elements of a tongue and groove connection system for connecting building modules to each other

420

concrete column

421

CLT wall

422

concrete wall

500

Magnified close-up

501

Aligned wood fibers of the chopped veneer type, of uniform shape and size

502

Aligned wood fibers, some fibers of which have the same shapes and sizes and some fibers have different shapes and sizes

503

Chip-like aligned wood fibers

504

multitude of layers of aligned wood fibers and binders

505

Strand-like aligned wood fibers

510

X-axis of the Cartesian coordinate system

520

Y-axis of the Cartesian coordinate system

530

Z-axis of the Cartesian coordinate system

540

row of six positions for corrugated casings

541

row of seven positions for corrugated casings

551

Curved wave with medium frequency

552

Low frequency curved wave

553

trapezoidal waves

554

square wave

555

triangle wave

556

sawtooth wave

557

Irregular Wave A

558

Irregular Wave B

559

Irregular Wave C

560

Irregular Wave D

561

Irregular Wave E

600

Zigzag line indicating a cut in the image

601

White arrow indicating the direction of movement

603

load resting on the supporting structural system

1A shows an exploded view in diagonal perspective of an embodiment of building module 2 comprising two layers - top plate 100 and base - wherein the base is a corrugated shell 201 of aligned chopped veneer wood fibers and binder formed by corrugations 221 of a curved wave in one direction combined with corrugations 227 of an irregular wave in another direction perpendicular to the first direction, together with an enlarged close-up view 500 of the aligned chopped veneer wood fibers 501 of the composite material of the base, wherein all of the aligned chopped veneer wood fibers have the same size shape.

1B is a diagonal perspective view of the same embodiment of the 1A illustrated two-layer building module 2, with dashed lines showing the base - which is a corrugated shell 201 of aligned wood fibers of the chopped veneer and binder type formed by corrugations 221 of a curved wave in one direction combined with corrugations 227 of an irregular wave in another direction perpendicular to the first direction - under the upper plate 100.

2 shows an image of the 3D model 4 of the design of a corrugated shell, which according to the present following disclosure is used as a base or core for a building module, after a digital optimization process in a virtual three-dimensional space within the Cartesian coordinate system, where dashed lines represent the X (510), Y (520) and Z (530) axes. In this 3D model 4 of a corrugated shell, corrugations 221 of a curved wave can be seen in one direction, combined with corrugations 227 of a composite wave in another direction perpendicular to the first direction.

3A shows an exploded view in diagonal perspective of another embodiment of the construction module 2 comprising two layers - a top plate 100 and a base -, the base being a corrugated shell 202 formed by corrugations 228 of an irregular wave in one direction combined with a corrugation 223 of a trapezoidal wave in another direction perpendicular to the first direction, and the entire peripheral surface of said corrugated shell ending flat and at its highest level. In this figure there is also shown an enlarged close-up 500 of the aligned wood fibers 502 of the composite material of the base, some fibers having the same shapes and sizes while others having different shapes and sizes.

3B shows a diagonal perspective view of the same embodiment of the 3A illustrated two-layer building module 2, wherein its upper plate 100 is connected to the corrugated shell 202 which forms its base.

3C represents a side elevation view of the same embodiment of the 3A and 3B illustrated two-layer construction module 2, wherein its upper plate 100 can be seen on the corrugated shell 202 and its corrugation 223 of a trapezoidal wave.

3D shows a front elevation view of the same embodiment of the 3A , 3B and 3C illustrated two-layer building module 2, with its upper plate 100 visible on the corrugated shell 202, as well as a front view of the corrugation 228 of an irregular wave which also forms the corrugated shell 202 in its other direction.

4 shows a diagonal perspective view from below of another embodiment of the building module 2 comprising two layers - top plate 100 and base -, the base being a corrugated shell 203 formed by corrugations 221 of a curved wave, the peripheral surface being raised on two of its four sides towards the top plate 100 so as to join with the latter and close said sides of the building module 2. An enlarged close-up 500 of the plurality of layers 504 of aligned fibers and binders comprised by the base and an enlarged close-up 500 of its splinter-like aligned fibers 503 are also shown.

5A shows a diagonal perspective view of another embodiment of the building module 2, comprising two layers - upper plate 100 and base -, wherein the base is a corrugated shell 200 formed by a corrugation 221 of a curved wave and is connected to the upper plate 100 with dowels 401.

5B is a diagonal perspective view of another embodiment of the building module 3 comprising three layers - upper plate 100, core and lower plate 300 - wherein the core is a corrugated shell 200 formed by a corrugation 221 of a curved wave in one direction and by corrugations 227 of an irregular wave in another direction perpendicular to the first direction, and connected to the upper plate 100 by bolts 402 and nuts 403.

6 provides a number of examples of some of the different types of regular waves that may be part of the shape of the corrugation(s) of the corrugated shell of the base or core of a building module. It is important to remember that these waves are only examples among many other types of waves that may be used in many different embodiments and should not be understood as a limiting collection of examples. Shown are a medium frequency curved wave 551, a low frequency curved wave 552, a trapezoidal wave 553, a square wave 554, a triangular wave 555 and a sawtooth wave 556.

Similarly, 7 provide a number of examples of some of the different types of irregular corrugations that may be part of the shape of the corrugation(s) of the corrugated shell of the base or core. It is important to remember that these corrugations are only examples within the endless types of possible irregular corrugations that may be used in various embodiments, and should not be understood as a limiting collection of examples. Irregular corrugations A (557), B (558), C (559), D (560), and E (561) are shown as an example, as they are depicted in some exemplary embodiments depicted in some other figures.

8A is an isometric view of another embodiment of the construction module 2, comprising send two layers - top plate 101 and base - wherein the base is a corrugated shell 200 formed by corrugations 221 of a medium frequency curved wave in a direction of the base perpendicularly intersecting other corrugations 222 of a low frequency curved wave, and wherein the top plate 101 is a CLT plate.

8B is an isometric view of another embodiment of the construction module 3, comprising the same elements of the 8A embodiment shown - an upper CLT plate 101 and a corrugated shell 200 formed by corrugations 221 of a medium frequency wave bent in one direction perpendicularly intersecting other corrugations 222 of a low frequency bent wave - and further comprising a third layer which is a lower plate 300 of smaller thickness and of a different material than the upper CLT plate 101.

9A shows an isometric view of another embodiment of the building module 2 comprising two layers - top plate 102 and base - wherein the base is a corrugated shell 200 formed by corrugations 221 of a curved wave in a direction of the base perpendicularly intersecting other corrugations 224 of a rectangular wave, and wherein the top plate 102 is a five-layer plywood panel.

9B is an isometric view of another embodiment of the construction module 3, comprising the same elements as those in 9A embodiment shown - a five-ply upper plywood panel 102 and a corrugated shell 200 formed by corrugations 221 of a medium frequency curved wave in a direction perpendicularly intersecting other corrugations 224 of a square wave - and further comprising a third layer which is a three-ply lower plywood panel 301.

10 shows a front perspective view of another embodiment of the building module 2 comprising two layers - top plate 100 and base 210 -, the base comprising two different overlapping corrugated shells. The corrugated shell connected to the top plate 100 is formed by corrugations 221 of a curved wave with medium frequency, while the second corrugated shell is formed by corrugations 229 of an irregular wave. In this figure, adhesive areas 400 can also be seen where the top plate 100 and the base 210 meet.

11 is a front perspective view of another embodiment of construction module 3 comprising three layers - upper plate 100, core 211 and lower plate 300 -, the core 211 consisting of two equal and mirror-stacked corrugated shells each formed by corrugations 221 of a medium frequency curved wave. In this figure it can also be seen that the present embodiment of construction module 3 further comprises cylindrical tongue and groove connecting means 410 for connecting to the concrete column 420. The white arrows 601 show the direction of movement of the module 3 towards its connecting position with the concrete column 420 and the zigzag lines 600 represent a section in the image.

12 is a front perspective view of another embodiment of building module 3 comprising three layers - top plate 100, core 212 and bottom plate 300 - wherein core 212 comprises four identical corrugated shells arranged adjacent to one another forming a pattern of four corrugated shells along the length of building module 3 with one corrugated shell across its width.

13 shows a front perspective view of another embodiment of the building module 3 comprising three layers - upper plate 100, core 213 and lower plate 300 - wherein the core 213 comprises six identical corrugated shells arranged in two mirrored overlapping layers, wherein in each layer three shells are arranged adjacent to one another.

14 shows an exploded front perspective view of another embodiment of the building module 3 comprising three layers - upper plate 100, core 214 and lower plate 302 - wherein the core 214 is a series of twenty-four adjacent corrugated shells of two different types arranged in an aligned pattern of six corrugated shells in one direction and four corrugated shells in another direction perpendicular to the first direction, their positions on the lower plate 302 being shown by dotted lines.

15 shows an exploded front perspective view of another embodiment of the building module 3 comprising three layers - upper plate 100, core 215 and lower plate 303 - wherein the core 215 is a row of twenty-six adjacent corrugated shells arranged in a non-aligned pattern of six and seven corrugated shells in one direction and four corrugated shells in another direction perpendicular to the first direction, the positions of which on the lower plate 303 are shown by dotted lines, with the row 540 of six positions and the row 541 of seven positions being highlighted.

16A is an exploded view in diagonal perspective of another embodiment of the building module 3 comprising three layers of the same material - upper plate 103, core and lower plate 304 - its core being a corrugated shell 204 - and further comprising two side plates 320. Also shown in this figure are three enlarged close-up views 500 of the aligned strand-like fibers 505 of the corrugated shell 204, the upper plate 103 and the lower plate 304.

16B is a diagonal perspective view of the same embodiment of the 16A illustrated construction module 3, showing its upper plate 103, the corrugated shell 204 of its core, the lower plate 304 and the two side plates 320 which are located between the short ends of the upper plate 103 and the lower plate 304 and are connected perpendicularly to them, so that the two shorter side surfaces of the construction module 3 are hidden.

17A shows an isometric exploded view of another embodiment of the building module 3, comprising three layers - upper plate 100, core and lower plate 300 -, the core being a corrugated shell 200 formed by corrugations 225 of a triangular wave, and further comprising two side plates 320 at their shorter ends.

17B is an isometric view of the same embodiment of the 17A illustrated building module 3, wherein the side plates 320 are connected to the upper 100 and lower plates 300 in a position perpendicular thereto, thereby concealing two of the side surfaces of the building element. It can also be seen that in this embodiment of the building module 3, the lower plate 300 is longer than the upper plate 100 and the corrugated shell 200 of the core, whereby the upper plate 100 and the core are located between the side plates 320, while the lower plate 300 is located below the side plates 320.

18A is an exploded isometric view of another embodiment of the building module (3) comprising three layers - top plate (104), core and bottom plate (305) - and further comprising four side plates (320). In this embodiment of the building module, the core is a corrugated shell (200) formed by corrugations (225) of a triangular wave, the top plate (104) being a fiber cement plate and the bottom plate (305) being a solid wood plate.

18B is an isometric view of the same embodiment of the 18A illustrated construction module 3, wherein the side plates 320 are connected to the upper plate 104 and the lower plate 305 in a position perpendicular to these, so that all four side surfaces of the construction module 3 are covered. It is also noted that in this embodiment of the construction module 3, the upper plate 104 and the lower plate 305 have the same size and the side plates 320 are located between them.

19A shows an isometric view of another embodiment of the building module 3, comprising three layers - upper plate 100, core and lower plate 300 -, the core being a corrugated shell 200 formed by corrugations 230 of an irregular wave, and further comprising two lateral plates 321 located between the upper plate 100 and the lower plate 300. In this figure it can be seen that the lower plate 300 has a greater width than the upper plate 100 and that the lateral plates 321 are connected to the upper plate 100 and the lower plate 300 in a position oblique to them, so that two of the lateral surfaces of the building module 3 are hidden.

19B is a side elevational view of the same embodiment of the 19A illustrated construction module 3, in which its side plates 321, its upper plate 100, its lower plate 300 and the corrugated shell 200 of its core - formed by corrugations 230 of an irregular wave - can be seen.

20 shows an isometric view of another embodiment of the building module 3 comprising three layers - upper plate 100, core and lower plate 300 -, the core being a corrugated shell 200 formed by corrugations 223 of a trapezoidal wave, and further comprising a single side plate 320 located between the upper plate 100 and the lower plate 300 in a position perpendicular to them, so that one of the side surfaces of the building module 3 is hidden.

21A shows an exploded front perspective view of another embodiment of the building module 2 comprising two layers - an upper plate 100 and a base - wherein the base is a corrugated shell 200 formed by corrugations 223 of a trapezoidal wave and has spring-like connecting elements 404 for connecting to the groove-like connecting elements 405 present in the upper plate 100.

21B shows a perspective front view of the same embodiment of the 21A shown construction module 2, wherein the upper plate 100 is guided in the direction of the white arrow 601 by means of its groove-like connecting elements 405 over the spring like connecting elements 404 slide on the corrugated shell 200 of the base.

21C shows a perspective front view of the same embodiment of the 21A and 21B illustrated construction module 2, wherein its upper plate 100, the corrugated shell 200 of its base and its corrugations 223 are shown in the form of a trapezoidal wave.

22A is a diagonal perspective view of another embodiment of the building module 2 comprising two layers - a top plate 110 with a convex shape and a base which is a corrugated shell 240 with an overall convex shape - such that the overall shape of the building module 2 of the present embodiment is convex.

22B is a diagonal perspective view of another embodiment of the construction module 3, comprising the same elements of the 22A illustrated embodiment - an upper plate 110 having a convex shape and a base which is a corrugated shell 240 having an overall convex shape - and further comprising a lower plate 310 having a convex shape, so that the entire shape of the building module 3 of the present embodiment is convex.

23 represents an isometric view of another embodiment of the building module 3 comprising three layers - upper plate 110, core and lower plate 300 -, the upper plate 110 having a convex shape, the lower plate 300 being flat and the core being a corrugated shell 200 formed by corrugations 231 of an irregular wave in one direction combined with other corrugations 231 of an irregular wave in another direction perpendicular to the first direction, with an overall convex upper region and a flat lower region, so that its shape matches the upper plate 110 and the lower plate 300 to which it is connected.

24 is an isometric view of another embodiment of the building module 3 comprising three layers - a top plate 111 of curved shape, a core which is a corrugated shell 241 of overall curved shape, and a bottom plate 311 of curved shape - together with two side plates 321 at two opposite ends of the module.

25 is an isometric view of another embodiment of the construction module 2 comprising two layers - an upper plate 111 of curved shape and a base which is a corrugated shell 209 of heterogeneous thickness and formed by corrugations 231 of an irregular wave, the upper part of which is curved so that its shape matches that of the upper plate to which it is connected.

26 shows an isometric view of another embodiment of the building module 3 comprising three layers - upper plate 111, core and lower plate 300 - wherein the upper plate 111 has a curved shape, the lower plate is flat and the core is a corrugated shell 200 whose upper portion is generally curved and whose lower surface is flat so that its shape matches the upper 111 and lower 300 plates to which it is connected.

27 shows an isometric view of another embodiment of the building module 3 comprising three layers - upper plate 111, core 211 and lower plate 311 - wherein the upper plate 111 and the lower plate 311 are identical and have a curved shape and are arranged in a mirrored arrangement and the core 211 consists of two identical corrugated shells stacked in a mirrored arrangement.

28 is a diagonal perspective view from below of another embodiment of the building module comprising three layers - upper plate 112, core and lower plate 312 - wherein the upper plate 112 and the lower plate 312 are the same and have a corrugated shape, and the core of which is a corrugated shell 241 with an overall corrugated shape, so that the entire shape of the building module 3 of the present embodiment is corrugated.

29 shows an isometric view of an embodiment of the construction system, wherein three identical construction modules 3 each with three layers can be seen, the core of which is a corrugated shell with corrugations 226 of a sawtooth wave. It can also be seen that spring-like connecting means 411 are connected to the lower plates of the construction modules 3 for connecting to the groove-like connecting elements 412 of other construction elements, which in this embodiment of the construction system is a CLT wall 421 to which the construction modules 3 are connected. The white arrows 601 show the downward positioning movement of the construction modules 3 in order to engage their spring-like connecting means 411 with the groove-like connecting elements 412 of the CLT wall 421. The zigzag line 600 represents a section in the image.

30A shows a trimetric exploded view of another embodiment of the construction module 2, comprising two layers - upper plate 100 and base -, the base being a corrugated shell 200. Also shown are four side plates 320 which run parallel to each other and two of which are located at each of the two shorter ends of the building module 2, so that together they configure a connecting element at each short end of the building module 2 for connecting to other building elements.

30B is a side elevational view of the same embodiment of the 30A illustrated construction module 2.

30C shows a trimetric view of another embodiment of the construction system, in which two construction modules 2, which form the 30A and 30B shown, connected to another construction module 3, which is the same type of construction module as the one shown in 29 embodiment shown, but in this case positioned vertically to act as a wall. An enlarged close-up elevation view 500 of the detail of the connection between the two types of building modules shown in this figure - 2 and 3 - is also shown, showing part of the corrugated shell 200 of the building module 2 and how its side panels 320 connected perpendicularly to its top panel 100 are connected to the building module 3 so as to configure a building system according to the present disclosure. The zigzag line 600 represents a section in the image.

31A 12 illustrates an isometric view of an embodiment of the building module having fasteners for connecting to other like building modules, showing two like three-layer building modules 3 with their respective top layers 100, their respective bottom layers 300, and their respective cores which are corrugated sleeves 205 of aligned bamboo chip type wood fibers and binder. It can be seen that the building modules 3 are connected to each other by tongue-like 413 and groove-like 414 fasteners so that when one of the building modules is loaded, both building modules flex as a unit and not independently of each other. Also shown is an enlarged close-up 500 of the elevational view of the connection between the two building modules with their tongue-like 413 and groove-like 414 fasteners, their respective top layers 100, their respective bottom layers 300, and their respective corrugated sleeves 205 of aligned bamboo chip type wood fibers and binder.

31B is a front elevation view of two modules of the same embodiment of the 31A building module 3 shown, separated by a white arrow 601 indicating the movement of one building module towards the other to connect with it. Also shown in this figure are their respective tongue-like 413 and groove-like 414 connecting elements, their upper plates 100, lower plates 300 and their cores which are corrugated sheaths 205 of aligned bamboo chip type wood fibers and binders.

32A shows a side elevation view of a two-layer embodiment of the structural load-bearing system 2, which consists of a top plate 100 that receives a load and transfers it to a base that is a corrugated shell 200 that acts together with the top plate 100 as a cooperating system to distribute the load throughout the system. It can be seen that the structural load-bearing system 2 is supported on two respective concrete walls 422 at two of its ends. It can be seen that a load 603 rests centered on the top plate 100 of the structural load-bearing system 2 and three dashed line arrows pointing downward within the load 603, indicating the direction of the forces exerted by the load 603 on the structural load-bearing system 2. Also present in the figure are smaller arrows indicating how the initial force exerted by the load 603 is divided and distributed through the base or corrugated shell 200 and across the top plate 100, mainly due to the membrane effect. The zigzag line 600 represents a cut in the image.

32B is a front elevation view of the same in 32A illustrated supporting structural system 2, which consists of two layers; a top plate 100 supported on the concrete wall 422 and a base, the base being a corrugated shell 200, which in this case is represented by dotted lines, meaning that it is located behind the concrete wall 422. The zigzag line 600 represents a cut in the image.

32C shows a side elevation view of a three-layer embodiment of the structural load bearing system 3, consisting of an upper plate 100, a core which is a corrugated shell 200, and a lower plate 300, which together serve as a cooperative system for load distribution throughout the system. It can be seen that the structural load bearing system 3 is supported on two concrete walls 422 over two of its ends. Also visible is a load 603 resting centered on the upper plate 100, as well as three dashed line arrows within the load 603 pointing downward and indicating the direction of the forces exerted by the load 603 on the structural load bearing system 3. Smaller arrows can also be seen illustrating how the initial force is divided and distributed throughout the structural load bearing system 3. The load 603 is taken up by the upper plate 100 and distributed via the corrugated shell 200 to the upper plate 100 and the lower plate 300. The corrugated shell 200 also serves as a separation between the upper plate 100 and the lower plate 300, representing a combination of compressive and tensile stresses that takes up part of the stresses from the lower plate 300 and in turn returns part of the stresses to the upper plate 100. The 3 layers of the load-bearing structural system 3 function mainly under membrane stresses and to a lesser extent by bending. The zigzag line 600 represents a cut in the image.

32D is a front elevation view of the same in 32C illustrated supporting structural system 3, which consists of three layers; an upper plate 100, a core which is a corrugated shell 200, and a lower plate 300 which is supported on the concrete wall 422. The zigzag line 600 represents a section in the image.

33 is a grayscale shaded diagonal perspective view of an exemplary corrugated shell according to the 1A , 1B , 16A and 16B illustrated embodiments.

34 is a grayscale shaded diagonal perspective view of another exemplary corrugated shell according to another embodiment.

35 is a grayscale shaded diagonal perspective view of another exemplary corrugated shell according to another embodiment, in which corrugations 230 of an irregular wave in one direction can be seen combined with other corrugations 227 of an irregular wave in another direction.

36 is a grayscale shaded diagonal perspective view of another exemplary corrugated shell according to another embodiment, showing corrugations 221 of a curved wave of medium frequency in one direction combined with other corrugations 227 of an irregular wave in another direction.

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• WO2011028124A1 [0008]
• DE202007001771U1 [0009]
• DE202018101347U1 [0010]

Cited non-patent literature

• Pramreiter et al. 2023 [0005]
• Shmulsky and Jones 2010 [0022]

Claims (28)

A structural composite building module comprising a top plate connected to a structural base made from a composite material containing aligned wood fibers and a binder. Structural composite module according to claim 1 , where the shape of the base and the general orientation of the aligned wood fibers are conscious and determined by parameters generated by digital or analog optimization tools. A structural composite module according to any preceding claim, wherein the oriented wood fibers are fibers of a type selected from the group consisting of whole fibers, refined fibers, fiber pieces, fiber bundles, cellulose fibers, bamboo fibers, bamboo chips, bamboo shavings, wood flakes, wood shavings, sawdust, wood strands, wood wool, wood chips, wood splinters, wood particles, wood veneer pieces, wood chips, wood sticks, sawdust and combinations thereof. A structural composite module according to any preceding claim, wherein the base comprises aligned fibers of a type selected from the group consisting of: a. fibers of the same size and shape; b. fibers of the same size and different shape; c. fibers of different sizes and the same shape; and/or d. fibers of different sizes and different shapes. A structural composite module according to any preceding claim, wherein the base comprises a plurality of layers of aligned wood fibers and binder. A structural composite module according to any preceding claim, wherein the base comprises at least one corrugated shell, and wherein said one corrugated shell comprises at least one corrugation formed by a type of wave selected from the group consisting of sine waves, square waves, trapezoidal waves, triangular waves, sawtooth waves, irregular waves, composite waves, and combinations thereof. Structural composite module according to claim 6 , wherein the at least one corrugation is arranged in at least one direction. A composite structural module according to any preceding claim, wherein the base comprises at least two corrugated shells, and wherein said at least two corrugated shells are arranged in a manner selected from the group consisting of shells stacked one above the other in two or more layers, shells arranged adjacent to one another within the same layer, and shells arranged adjacent to one another within the same layer and having other shells stacked thereon in two or more layers. Structural composite module according to claim 8 wherein the at least two corrugated sleeves are further arranged in a manner selected from the group consisting of aligned with each other, non-aligned with each other, and/or combinations thereof. A structural composite building module according to any preceding claim, further comprising at least one side panel connected to the top panel in a vertical or oblique position such that at least one of the side surfaces of the building module is concealed. A structural composite building module according to any one of the preceding claims, wherein its top plate is a plate of a type selected from the group consisting of plywood, solid wood, OSB, CLT, particle board, fiber cement board, concrete board, WPC board, a composite board, a polymer board, a biopolymer board, a polymer composite board and a plate of the same type of material as the material of the base. Structural composite module according to one of the Claims 6 until 11 wherein at least a portion of the peripheral surface of the at least one corrugated shell is a flat, continuous surface and has a height equal to or greater than the height of the highest crests of the corrugated shell, such that said at least one portion of the peripheral surface is the connection surface between the at least one corrugated shell and the top plate. Structural composite module according to one of the Claims 6 until 12 wherein at least one of the crests and/or valleys of the at least one corrugated shell comprising the base has a flat surface parallel to the surface of the top plate. Structural composite module according to one of the Claims 6 until 13 wherein the base is connected to the top plate at the crests of all or some of the at least one corrugation of its at least one corrugated shell. A structural composite building module according to any preceding claim, wherein the shape of its top plate is a shape selected from the group consisting of concave shape, convex shape, curved shape, flat shape, corrugated shape, irregular shape and combinations thereof. A structural composite module according to any preceding claim, wherein the thickness of the base is non-uniform. A structural composite module according to any preceding claim, further comprising connecting means for connecting to at least one element selected from the group consisting of walls, beams, columns, supports, panels, floor slabs, floors, ceilings, roofs and other structural composite modules. A structural composite module according to any preceding claim, wherein the specific shape of the base and the specific shape, position and orientation of each of its aligned wood fibers are intentional and determined by parameters generated by means of digital or analog optimization tools. A structural composite module according to any preceding claim, further comprising a bottom plate connected to the underside of the base, the base forming a core of a three-layer structural composite module. Structural composite module according to one of the Claims 6 until 19 , wherein the arrangement and type of corrugations of the corrugated sheath or sheaths contained in the base or core have gaps between the corrugated sheath and the upper and/or lower boards so that cable ducts, cables and the like can be led from one side of the building module to at least one other side of the building module. A load-bearing structural system comprising: a base consisting of at least one corrugated shell comprising aligned wood fibers and binder, which is connected on its upper side to the lower side of a top plate; a top plate, mounted in the upper region of the system, which takes up the load and is a plate of a type selected from the group consisting of plywood, solid wood, OSB, CLT, particle board, fiber cement board, concrete board, WPC board, a composite board, a polymer board, a biopolymer board, a polymer composite board and a board of the same type of material as the material of the base; and connecting means connecting the top plate to the base; wherein at least one of the sides of the perimeter of the system rests and/or is fixed on another structural element, and the upper plate, when it receives a load, transmits the forces derived from said load to the at least one corrugated sheath, the configuration and the orientation of its fibers of which are deliberately determined by parameters generated by means of digital or analog optimization tools, in order to absorb said forces and distribute them throughout the system mainly by the membrane effect, so that all parts of the system cooperate together through the action of the connecting elements and the load-bearing capacity of the system is maximized. Load-bearing structural system according to claim 21 , wherein the oriented wood fibers are fibers of a type selected from the group consisting of whole fibers, refined fibers, fiber pieces, fiber bundles, cellulose fibers, bamboo fibers, bamboo chips, bamboo shavings, wood flakes, wood shavings, sawdust, wood strands, wood wool, wood chips, wood splinters, wood particles, wood veneer pieces, wood chips, wood sticks, sawdust, and combinations thereof. Load-bearing structural system according to one of the Claims 21 or 22 , further comprising at least one side plate connected to the top plate in a vertical or inclined position so that at least one of the side surfaces of the system is concealed. Load-bearing structural system according to one of the Claims 21 , 22 or 23 , wherein the specific shape of the at least one corrugated shell and the specific shape, position and orientation of each of the aligned wood fibers are intentional and determined by parameters previously generated using digital or analog optimization tools. Load-bearing structural system according to one of the Claims 21 , 22 , 23 or 24 , further comprising a second panel of a type selected from the group consisting of plywood, solid wood, OSB, CLT, particle board, fiber cement board, concrete board, WPC board, a composite board, a polymer board, a biopolymer board, a polymer composite board and a panel made of the same type of material as the material of the base, which is located in the lower region of the supporting structural system and is connected to the underside of the at least one corrugated shell of its base, so that the at least one corrugated shell keeps the two panels separated from each other and also transfers part of said forces to said second panel. which in turn also distributes part of the said forces to the system as a whole. A modular building system comprising: a plurality of structural composite building modules according to any of the Claims 1 until 20 ; and connecting means; wherein the structural composite modules are structurally connected by the connecting means. Modular construction system according to claim 26 , where the structural composite modules serve as walls, slabs, ceilings, floors, bridges, beams, columns, supports, doors and/or inclined planes. Modular construction system based on one of the Claims 26 or 27 , where the structural composite modules are connected to other building elements made of other materials and/or to existing buildings.

Images