GB2470734A

GB2470734A - A stackable building module

Info

Publication number: GB2470734A
Application number: GB0909442A
Authority: GB
Inventors: Mart De Jong
Original assignee: COCON IP DEV Ltd
Current assignee: COCON IP DEV Ltd
Priority date: 2009-06-02
Filing date: 2009-06-02
Publication date: 2010-12-08
Also published as: GB0909442D0

Abstract

A building module 2 comprising a frameless self-supporting shell constructed from laminate panels of composite material wherein the module is adapted to bear load of at least one other module to allow stacking. Preferably the laminate panels include an outer skin enclosing a polyisocyanurate (PIR) foam core, where the outer skin comprises a combination of chapped strand mat (CSM), unidirectional and multidirectional woven materials, a polyester or vinylester resin and polyurethane gel coating. The outer skin may also include a fire resistant textile. It is also preferable that the laminate panels include fixing strips arranged around the periphery of the panel and disposed partially within the panel, where the fixing strips are either made from pine or plastic. A separator device 5, a method of constructing a modular building and a modular building 1 is also claimed.

Description

A building module and a method of constructing a modular building This invention relates to modular buildings. More specifically, this invention relates to a prefabricated building unit and a method of constructing a flexible-use semi-permanent building from a plurality of separate building modules.

Due to increases in the transportation costs of building materials and building waste, there has been a rise in the demand for cost effective prefabricated housing. In addition to this, the apparent increase in the number and scale of natural disasters has led to a greater need for low cost, easily transported, transitional sheltering and temporary housing.

A conventional method of constructing a modular building, for example a complex of studio residences, uses prefabricated self-contained studio boxes.

An example of such a conventional building structure is shown in Figure 1. Here, a modular construction 100 comprises a plurality of individual self-contained studio units 200 that are stacked in columns of three. The building is constructed by assembling columns adjacent to one another.

Figure 2 shows a schematic cross-sectional view of a typical studio unit 200. The studio unit 200 is constructed from composite panels: side panels 210 and horizontal panels 220. The front 201 and rear 202 of each studio unit 200 are also constructed from composite panels, and generally include a window and a door respectively. For simplicity these have not been shown in the figures.

With reference to Figures 8A and 8B, panels 210 and 220 comprise and outer skin 240 enclosing and inner core 250. Typically, the outer skin 240 is a sheet of polyester laminate, and the inner core 250 comprises polyisocyanurate (PIR) foam.

Peripheral regions of the panels include wooden inserts 260. These enable a side panel 210 to be secured to a horizontal panel 220 via glue 270 and/or bolt 280.

Figure 3 shows a cross-sectional view along the line A-A shown in Figure 1. Each side panel 210 includes two hollow-section steel posts 290 enclosed within the panel; one post is disposed towards the front of the studio unit 200, and the other is positioned towards the rear of the studio unit 200. For simplicity, only the forward posts 290 are shown in the figures.

During construction of a conventional modular building, a crane lowers a ground floor studio unit onto a foundation plate. A first floor studio unit is then lowered onto the ground floor unit with upper ends 291 of each ground floor post 290 being inserted into a lower end 292 of a corresponding first floor post 290. In the same way, a second floor unit is lowered into position atop the first floor unit.

Concatenating successive studio units in this way allows the weight of the whole structure to be borne by the interconnected front and rear steel posts.

A problem arises with this conventional construction of a modular building in that the steel posts form a "cold bridge" within the studio unit panels. This encourages the growth of salts and fungi in the region of the panel where the post and composite material meet. This problem increases the likelihood of panel delamination.

In addition to the above, a further problem arises with the prior art construction in that the steel posts provide an ingress for moisture and water that leads to oxidation of the steel. This process also increases the risk of panel delamination.

It is an object of the present invention to provide an improved modular building construction that addresses some or all of the aforementioned problems.

According to an aspect of the present invention there is provided a building module comprising a frameless self-supporting shell constructed from laminate panels of composite material, wherein said self-supporting shell is adapted to bear the load of at least one other building module.

Preferably, the laminate panels include an outer skin enclosing a foam core.

In a preferred embodiment the outer skin comprises a combination of chopped strand mat (CSM), unidirectional and multi-directional woven materials (rovings), and a resin, for example a polyester or a vinylester resin.

In an alternative embodiment the outer skin comprises a polyurethane gel coating.

Preferably, the core material is polyisocyanurate (PIR) foam.

Advantageously, the outer skin may include a fire retardant product, for example a fire resistant textile.

Preferably, the laminate panels include fixing strips arranged around the periphery of the panel and disposed at least partially within the panel.

The fixing strips may be wooden inserts, for example strips made from pine or, alternatively, the fixing strips may be constructed from a plastics material.

According to a further aspect of the present invention, there is provided a method of constructing a modular building comprising: providing a plurality of building modules, wherein each building module is a frameless self-supporting shell constructed from laminate panels of composite material; and placing one building module on top of another building module with at least one separator device disposed therebetween.

Preferably, the separator device includes resilient means and a retainer that holds the resilient means in place.

In a preferred embodiment the resilient means comprises a first resilient means and a second resilient means, and the retainer is interposed between the first resilient means and the second resilient means.

Preferably the first resilient means comprises a rubber block, and the second resilient means comprises a rubber block. Alternatively, the first resilient means and the second resilient means each comprise a pair of spaced-apart rubber blocks.

Preferably, the retainer is a steel member bridging adjacent building modules.

Advantageously, the steel member has an I-profile providing retaining walls for engagement with the resilient means.

In a preferred embodiment, the method includes securing a plurality of rubber blocks to a roof panel of a first building module; placing one of a plurality of I-profile steel members over each of the plurality of rubber blocks; securing a plurality of rubber blocks to the underside surface of a floor panel of a second building module; aligning corresponding rubber blocks of the first and second building modules; and lowering the second building module onto the first building module such that each of the plurality of rubber blocks on the underside surface of the floor panel of the second building module come to rest on an upper surface of each I-profile steel member associated with a corresponding rubber block of the roof panel of the first building module.

Preferably, each I-profile steel member forms a bridge between adjacent rubber blocks of an adjacent building module.

According to another aspect of the present invention, there is provided a separator device for placement between building modules of a modular building, the separator device comprising resilient means and a retainer that holds the resilient means in place.

According to a further aspect of the present invention, there is provided a modular building comprising a plurality of building modules stacked one on top of the other, wherein each of the plurality of building modules is a frameless self-supporting shell constructed from laminate panels of composite material, and at least one separator device is disposed between each of the plurality of building modules.

Preferably, the retainer is a steel member bridging adjacent building modules.

In a preferred embodiment, the modular building includes a plurality of rubber blocks secured to a roof panel of at least a first building module; an I-profile steel member interposed between a plurality of rubber blocks secured to the underside surface of a floor panel of at least a second building module placed atop the at least first building unit; wherein corresponding rubber blocks of the at least first and the at least second building modules are aligned.

An embodiment of the present invention will now be described, by way of example only, and with reference to the accompanying schematic drawings, in which: Figure 1 is a perspective view of a conventional modular building; Figure 2 shows a cross-sectional view of a building module of the conventional modular building of Figure 1; Figure 3 shows the a cross-sectional view through the line A-A of Figure 1; Figure 4 shows a perspective view of an embodiment of a modular building of the present invention; Figure 5 shows an exploded view of a separator device of the present invention; Figure 6 shows a partially exploded view of a separator device of the present invention; Figure 7A shows a partial front elevation view of a separator device of the present invention in situ linking adjacent building modules between two tiers of a modular building; Figures 7B shows a partial side elevation view of a separator device of the present invention in situ between two tiers of a modular building; Figure 7C shows a partial cross-sectional view of a separator device of the present invention in situ between two tiers of a modular building; Figure 8A shows a partial cross-sectional view of a side panel and a horizontal panel of a building module adjoined using glue; and Figure 8B shows a partial cross-sectional view of a side panel and a horizontal panel of a building module adjoined using glue and a bolt.

Referring to Figure 4, a modular building 1 according to the present invention comprises a plurality of stacked building modules 2 arranged in adjacent columns 4.

Between each building tier, and bridging each column 4 within each tier, is a plurality of separator devices 5.

Unlike the modular building shown in Figure 3, the modular building of the present invention does not require any internal steel posts to provide support or structural integrity to the building.

Each building module 2 is constructed from composite, structurally insulated panels that are bolted and/or glued together at a remote location. The construction of these prefabricated building modules differ from those of the prior art in that they do not have any internal steel structure, and the panels from which the modules are made include a foam core whose width is greater than or equal to 80mm.

In preferred embodiments, the core of each composite panel comprises a layer of polyisocyanurate (PIR) foam. This PIR foam core is sandwiched between and outer skin of polyester laminate composed of layers of glass fibre materials and a high performance polyurethane resin. The skin material completely encases the core foam so that each panel is weatherproof. Generally, these panels are constructed using the Seeman Composites Resin Infusion Moulding Process (SCRIMP).

Advantageously, the panels of the building modules of the present invention include a fire resistant material within the laminate structure of the panel. In a preferred embodiment of the building module, this material is Firetexx� cloth that is introduced during the SCRIMP.

As shown in Figures 8A and 8B, each panel 210, 220 includes wooden inserts 260 that form part of the laminate structure of the panel. Typically these inserts will be strips of pine, however it is envisaged that they may be formed of any suitable plastics material, especially a recycled plastics material that will help to reduce the overall cost of each panel. Plastics materials have the advantage of being strong but light, and they tend to degrade at a much slower rate than other materials.

The wooden inserts 260 enable other structures, such as door and window frames, to be attached to the panels. Furthermore, the wooden inserts 260 also provide the panels with a strong, impact resistant, peripheral edge. During construction of the building modules, the wooden inserts provide locations for joining adjacent panels together, either by the use of a semi-rigid polyurethane glue 270 alone (Fig. 8A), or in combination with a bolt fixing 280 (Fig. 8B). Alternatively, the panels can be joined together using just fixing bolts without the use of any form of glue or fixative.

As shown in Figures 5 and 6, a separator device 5 comprises an I-profile steel member 6 and four rubber blocks 7. Each rubber block 7 includes a centre hole 9 for receiving a fixing bolt 8 (see Figure 7C).

During construction of a modular building, rubber blocks 7 are secured to the outer surface of roof panels of lower tier building modules 2 using bolts 8. Building modules 2 forming the upper tier have rubber blocks 7 secured to the outer surface of floor panels also via bolts 8. Alternatively, the blocks can be secured in place using a fixative alone, for example a semi-rigid polyurethane glue, or in combination with a bolt or other such suitable fastener.

Adjacent building modules 2 are bridged using I-profile steel members 7, and upper tier building modules 2 are lowered onto lower tier building modules 2 such that corresponding upper and lower tier rubber blocks 7 align as shown in the figures.

Figure 7A shows a partial front elevation view of the junction between adjacent building modules and between upper and lower tiers of building modules. Vibrational noise from an upper tier is damped via the twin layers of plastic blocks between upper and lower building modules. Furthermore, the use of steel members combined with the self-supporting structure of each building module 2 negates the requirement of providing steel support posts within the constituent side panels of each module.

Figure 7B is a side elevation view of a separator device in place between an upper tier building module and a lower tier building module.

Figure 7C is a cross-sectional view through the separator device of Figure 7B showing fixing bolts 8. The fixing bolts 8 are secured into the floor panel and roof panel of a lower tier module and an upper tier module respectively.

In an alternative embodiment, the separator device 5 comprises a single upper rubber block and a single lower rubber block. In this case both the upper and lower rubber blocks include a pair of spaced-apart holes for receiving two fixing bolts.

Claims

Claims 1. A building module comprising a frameless self-supporting shell constructed from laminate panels of composite material, wherein said self-supporting shell is adapted to bear the load of at least one other building module.
2. A building module as claimed in claim 1, wherein the laminate panels include an outer skin enclosing a foam core.
3. A building module as claimed in claim 2, wherein the outer skin comprises a combination of chopped strand mat (CSM), unidirectional and multidirectional woven materials, and a resin.
4. A building module as claimed in claim 3, wherein the resin is a polyester or a vinylester resin.
5. A building module as claimed in claim 2, wherein the outer skin comprises a polyurethane gel coating.
6. A building module as claimed in claim 2, wherein the core material is polyisocyanurate (PIR) foam.
7. A building module as claimed in any claim 2 to 6, wherein the outer skin includes a fire resistant textile.
8. A building module as claimed in any previous claim, wherein the laminate panels include fixing strips arranged around the periphery of the panel and disposed at least partially within the panel.
9. A building module as claimed in claim 8, wherein the fixing strips are wooden inserts.
10. A building module as claimed in claim 9, wherein the inserts are made from pine.
11. A building module as claimed in claim 8, wherein the fixing strips are constructed from a plastics material.
12. A method of constructing a modular building comprising: providing a plurality of building modules, wherein each building module is a frameless self-supporting shell constructed from laminate panels of composite material; and placing one building module on top of another building module with at least one separator device disposed therebetween.
13. A method of constructing a modular building as claimed in claim 12, wherein the separator device includes resilient means and a retainer that holds the resilient means in place.
14. A method of constructing a modular building as claimed in claim 13, wherein the resilient means comprises a first resilient means and a second resilient means, and the retainer is interposed between the first resilient means and the second resilient means.
15. A method of constructing a modular building as claimed in claim 14, wherein the first resilient means comprises a rubber block, and the second resilient means comprises a rubber block.
16. A method of constructing a modular building as claimed in claim 14, wherein the first resilient means and the second resilient means each comprise a pair of spaced-apart rubber blocks.
17. A method of constructing a modular building as claimed in any claim 14 to 16, wherein the retainer is a steel member bridging adjacent building modules.
18. A method of constructing a modular building as claimed in claim 17, wherein the steel member has an I-profile providing retaining walls for engagement with the resilient means.
19. A method of constructing a modular building as claimed in any claim 14 to 18, wherein the method includes: securing a plurality of rubber blocks to a roof panel of a first building module; placing one of a plurality of I-profile steel members over each of the plurality of rubber blocks; securing a plurality of rubber blocks to the underside surface of a floor panel of a second building module; aligning corresponding rubber blocks of the first and second building modules; and lowering the second building module onto the first building module such that each of the plurality of rubber blocks on the underside surface of the floor panel of the second building module come to rest on an upper surface of each I-profile steel member associated with a corresponding rubber block of the roof panel of the first building module.
20. A method of constructing a modular building as claimed in claim 19, wherein, each I-profile steel member forms a bridge between adjacent rubber blocks of an adjacent building module.
21. A separator device for placement between building modules of a modular building, the separator device comprising resilient means and a retainer that holds the resilient means in place.
22. A separator device as claimed in claim 21, wherein the separator device includes resilient means and a retainer that holds the resilient means in place.
23. A separator device as claimed in claim 22, wherein the resilient means comprises a first resilient means and a second resilient means, and the retainer is interposed between the first resilient means and the second resilient means.
24. A separator device as claimed in claim 23, wherein the first resilient means comprises a rubber block, and the second resilient means comprises a rubber block.
25. A separator device as claimed in claim 23, wherein the first resilient means and the second resilient means each comprise a pair of spaced-apart rubber blocks.
26. A separator device as claimed in any claim 21 to 25, wherein the retainer is a steel member bridging adjacent building modules.
27. A separator device as claimed in claim 26, wherein the steel member has an I-profile providing retaining walls for engagement with the resilient means.
28. A modular building comprising a plurality of building modules stacked one on top of the other, wherein each of the plurality of building modules is a frameless self-supporting shell constructed from laminate panels of composite material, and at least one separator device is disposed between each of the plurality of building modules.
29. A modular building as claimed in claim 28, wherein the separator device includes resilient means and a retainer that holds the resilient means in place.
30. A modular building as claimed in claim 29, wherein the resilient means comprises a first resilient means and a second resilient means, and the retainer is interposed between the first resilient means and the second resilient means.
31. A modular building as claimed in claim 30, wherein the first resilient means comprises a rubber block, and the second resilient means comprises a rubber block.
32. A modular building as claimed in claim 30, wherein the first resilient means and the second resilient means each comprise a pair of spaced-apart rubber blocks.
33. A modular building as claimed in any claim 28 to 32, wherein the retainer is a steel member bridging adjacent building modules.
34. A modular building as claimed in claim 33, wherein the steel member has an I-profile providing retaining walls for engagement with the resilient means.
35. A modular building as claimed in any claim 28 to 34, wherein the modular building includes: a plurality of rubber blocks secured to a roof panel of at least a first building module; an I-profile steel member interposed between a plurality of rubber blocks secured to the underside surface of a floor panel of at least a second building module placed atop the at least first building unit; wherein corresponding rubber blocks of the at least first and the at least second building modules are aligned.
36. A modular building as claimed in claim 35, wherein each I-profile steel member forms a bridge between adjacent rubber blocks of an adjacent building module
37. A building module as substantially hereinbefore described with reference to, and as illustrated by, the accompanying drawings.
38. A method of constructing a modular building as substantially hereinbefore described with reference to, and as illustrated by, the accompanying drawings.
39. A separator device for placement between building modules of a modular building as substantially hereinbefore described with reference to, and as illustrated by, the accompanying drawings.
40. A modular building as substantially hereinbefore described with reference to, and as illustrated by, the accompanying drawings.