MXPA97008507A - Modu construction structure - Google Patents

Abstract

A modular construction structure comprising structural sub-frames and interconnection plates. The sub-frames have an open construction, and are made in a standard size to reduce the number of components required to build a building. The interconnection plates are of three designs: a supported beam (22), a flange plate (33), and a wall plate (21). The modular construction structure can easily be extended up to two or more floors. The same structure can form walls, floor, internal ceiling, and the external ceiling

Description

MODULAR CONSTRUCTION STRUCTURE FIELD OF THE INVENTION This invention relates to construction structures, and in particular, to a modular construction structure that can be erected rapidly with minimal effort and labor. The invention will find application in a range of construction situations, including domestic room, industrial housing, and farm structures.

BACKGROUND OF THE INVENTION Various attempts have been made to develop modular construction systems. The primary problem with the attempts of the prior art has been the drawbacks with the structural integrity of the resulting structure. Another difficulty is that the known systems are not truly modular, since they are difficult to erect, and very difficult to modify once erected. The inventors are aware of United States Patent Number 4,858,398 in the name of Ricchini, which describes a prefabricated modular construction system that solves the problem of structural integrity by constructing panels of frame members in the form of a channel. they surround a rigid insulating core with protective surface layers laminated on both sides. This approach has two main problems. First, there is the difficulty in providing a weatherproof seal between the panels. Second, the resulting structure requires internal beams to support the roof structure. Both characteristics are undesirable. The inventors are also aware of U.S. Patent No. 5,072,554 to Hayman, which refers to a prefabricated modular storage building constructed of a number of panels that are interlocked by means of a flange and channel configuration. This invention suffers from problems similar to that described above, as well as being particularly difficult to assemble. Modular frame systems, such as those described by De Blan in International Patent Application Number WO 29537/94, are intended to provide savings in handling, storage, and transportation, by performing a number of construction tasks in a manufacturing workshop, and then transport the prefabricated modules to the construction site. Even if the declared objective is achieved, at least in part, they do not provide a particular advantage in terms of ease of construction or cost of materials.

Another prior art system known to the inventors is that described in International Patent Application Number WO 95/02097 (PCT / AU94 / 00335) in the name of Leftminster Pty Ltd. The Leftminster system is based on wall panels, prefabricated floor and roof transportable. In the Leftminster system, the panels required for a particular structure are designed and constructed before being transported to the erection site. The prefabricated panels are erected on the site on prepared floor support bases. The Leftminster system is not modular, as it is not based on a standard set of panels. In addition, it requires a large number of separate components, including beams (or beams) to support the roof. Although the Leftminster application describes a prefabricated construction system that has some improvements over the known metal frame constructions, it fails to capture an advantage due to the complexity of the construction on the site, and the wide variety of components required. The need for a roof structure in the form of beams for structural integrity severely limits the versatility and applicability of the system. In general, the previous construction techniques require a complex set of components, including posts, plates, battens, crossbeams, nuts and bolts, beams, coatings, and so on. The large number of components requires that the constructor spend a considerable amount of time adjusting them to each other. In addition, the known modular structures are usually limited to the specific structural coating that is essential to add strength to the building. Also, once erected, the structures are difficult to extend.

OBJECT OF THE INVENTION It is an object of the present invention to provide a modular construction structure that has minimal components, and that forms a structure that does not require the use of coatings or reinforcements to provide structural integrity. It is a further object of the invention to provide a modular construction structure that is simple and quick to assemble or disassemble, compared to previous known systems. It is a still further object of the invention to provide a modular construction structure that provides ease of structural modification. Other objects will be evident from the following discussion.

DESCRIPTION OF THE INVENTION In one form, although it need not be the only or really the most extensive form, the invention resides in a modular construction structure comprising structural sub-frames and interconnection plates; these structural sub-frames of an open construction having a previously determined configuration; these structural sub-frames can be connected in a removable manner to form the construction structure, including walls and roof; wherein the wall sub-frames are connected in a removable manner to form wall structures, the roof sub-frames are connected in a removable manner to the wall sub-frames by means of first interconnection plates, and the sub-frames adjacent roofs that are in a flange are removably connected by second interconnecting plates to form a roof structure; the connection of the sub-frames with the sub-frames and the sub-frames with the interconnection plates by means of removable fixing elements; wherein the structural integrity of the construction structure is provided by the interconnected sub-frames without the need for coating or reinforcement. Structural subframes preferably comprise perimeter members and internal members. The perimeter members adequately perform a structural role, and the internal members provide coating support. The roof structure is adequately provided by the interconnected sub-frames without the need for beams or reinforcement. The modular construction structure may further comprise an internal roof structure formed of interconnected sub-frames. The structural integrity of the construction structure can be provided by the interconnected sub-frames that form the wall structures and the internal roof structure. Preferably, the external roof structure is not required for the structural integrity of the building structure when it comprises an internal roof structure. Preferably, the structural sub-frames are assembled from materials having a high tensile strength, such as metal sections, carbon fiber beams, synthetic wood, plastic, or other modern construction material. The sub-frames can be constructed according to the evaluation of the appropriate wind code. Preferably, the construction structure has an evaluation of the wind code up to W70. Structural subframes are suitably made in a number of standard sizes and configurations. The sub-frames are properly prefabricated and kept in storage with a supply of prefabricated interconnection plates. Preferably, a third interconnection plate is provided adapted to removably connect the standard sub-frames to form sub-frames in combination. Preferably, the structural sub-frames are interconnected to form internal wall structures, internal roof structures, and external roof structures, without additional structural components. The resulting structure can be suitably coated with any desired material without considering the structural properties of the coating. Preferably, the modular construction structure is erected on the site on bolts emptied into a thickened shore or on a concrete foundation. The second interconnection plate preferably comprises a flange plate with a roof inclination of between 15 ° C and 50 ° C. In a further form, the invention resides in a method for constructing a modular building, which includes the steps of: building a plurality of sub-frames, these sub-frames being of an open construction, and having a predetermined configuration; removably connecting the adjacent wall sub-frames to form the wall structures; removably connect the roof sub-frames with the wall sub-frames, with first interconnection plates; removably connect the adjacent roof sub-frames to form a roof structure; and - removably connect the cover with the sub-frames to form a building. Preferably, the step of removably connecting the adjacent roof sub-frames to form a roof structure includes the step of removably connecting the roof sub-frames that are on a flange with second interconnecting plates. Preferably, the method further includes the steps of removably connecting other sub-frames to form internal wall structures, external roof structures, or internal roof structures. The method may further include the step of removably connecting sub-frames with sub-frames, with third interconnection plates, to form larger structures. In a still further form, the invention resides in a method for extending a modular building, which includes the steps of: stopping the covering of a modular building structure; disconnect one or more sub-frames from the adjacent sub-frames and from the interconnection boards; connect additional sub-frames to existing sub-frames to extend the modular construction structure; reconnect the disconnected sub-frames; and join the coating to finish the extended modular building.

BRIEF DETAILS OF THE DRAWINGS To assist in understanding, preferred embodiments of the invention will now be described with reference to the following figures, in which: Figure 1 is a schematic of a standard wall subframe. Figure 2 shows the method to form a sub-frame. Figure 3 is a schematic of a standard wall sub-frame that includes a door and a window space. Figure 4 is a schematic of a standard roof sub-frame. Figure 5 is an isometric view of a housing construction incorporating a variety of standard sub-frames.

Figure 6 is a schematic of a supported beam. Figure 7 is a schematic of a flange plate. Figure 8 is a schematic of an extension plate. Figure 9 is a sectional view of a portion of an assembly of sub-frames. Figure 10 shows the configuration of a typical base. Figure 11 is a series of figures demonstrating the method of construction of a housing. Figure 12 is a part separated view of a modular construction structure for a house. Figure 13 is an isometric view of an alternative housing construction. Figure 14 is a schematic of a flange plate for the housing of Figure 13. Figure 15 is tabulating the construction data.

DETAILED DESCRIPTION OF THE DRAWINGS In the drawings, the same reference numerals refer to equal parts. For simplicity of explanation, reference will be made to sub-frames constructed of profiled "C" steel channel members. The adjacent members are welded to form the sub-frames. Although the preferred embodiment refers to steel channel members of specific dimensions, it will be apparent that other dimensions or other materials will be appropriate, depending on the load carrying capacity required. The weld can also be replaced by equivalent means, such as screwing or compression, to assemble the su-frames. Referring to Figure 1, a typical wall sub-frame comprising perimeter members constructed of steel channel sections of 150 millimeters, a thickness of 1.9 millimeters, indicated as 1, and a thickness of 1.0 millimeters is shown. , indicated as 2. The sub-frames are formed with the channel sections having the "C" side inwards. The internal members 3 are channel sections of 100 millimeters of a thickness of 1.5 millimeters. The channel sections are butt welded 4 as shown in Figure 2. Perimeter members 1, 2 perform a structural role forming a portal-shaped arch, and when constructed on a concrete slab, with stringers or stumps , which provide a strong hold down. The internal members generally act as overlay supports in a manner similar to dowels, crossbars, belts, reinforcement splints, heads, shelves, and sills. The wall sub-frames of Figure 1 are formed into a standard size of 3,000 millimeters wide by 3,000 millimeters high. To facilitate the construction of a variety of structures, the sub-frames are made in standard widths of 600 millimeters, 900 millimeters, 1,500 millimeters, 2,400 millimeters, 2700 millimeters, and 3,000 millimeters, and in standard heights of 2,400 millimeters, 2,700 millimeters, and 3,000 millimeters. For a special construction, it can be made 1/2 of the size or 1/4 of the size. The modular nature of the construction structure allows a supply of sub-frames and interconnection plates to be prefabricated in previously determined configurations. The sub-frames and interconnection plates required for a building are then supplied directly from the warehouse, as opposed to being manufactured for the purpose as in the prior art systems. This configuration also has the advantages of achieving plumb and square in the modular construction structure, because it is constructed of material previously manufactured from a previously determined configuration with factory tolerances. The inventors have discovered that only three basic types of sub-frames are required, and these are: a. sub-frames C10015, comprising perimeter members of 1.5 millimeters in thickness, channels of section C of 100 millimeters, and internal members of 1.5 millimeters in thickness, channels of section C of 100 millimeters, - b. sub-frames C15015 comprising perimeter members of 1.5 millimeters thick, 150-millimeter section C channels, and 1.5 millimeter thick internal members, 150-millimeter section C channels; and c. sub-frames C15019P comprising perimeter members of 1.9 millimeters in thickness, channels of section C of 150 millimeters, and internal members of 1.5 millimeters in thickness, channels of section C of 150 millimeters. Figure 3 shows a sub-frame of 3,000 millimeters wide by 3,000 millimeters in height, with a window space. As with the full-wall sub-frame of Figure 1, the perimeter members 5 of the sub-frame are channel sections of 150 millimeters, 1.5 millimeters thick (or 1.9 millimeters for the higher wind assessments), the remaining members being of a lighter caliber. The roof sub-frames are formed in a similar way to wall sub-frames. The roof sub-frame illustrated in Figure 4 is formed as 3,000 millimeters by 3,000 millimeters. The sub-frame is formed by sections of "C" channel 150 millimeters, 1.5 millimeters (or 1.9 millimeters) thick. A building 6 formed of a number of standard sub-frames, are shown in Figure 5. The building is made of 2 identical sub-frames 7 designed with a space for garage door. A door sub-frame 8 and a window eub-frame 9 are formed on one side of the building. The remaining sides (not visible) are identical to the standard sub-frame of Figure 1. 4 identical roof sub-frames 10 form the roof. The filling sub-frame 11 completes the modular construction structure. The wall sub-frames are removably connected to the attached roof sub-frames by supported beams 12, as shown schematically in Figure 6. For the sub-frames described above, the supported beams are made of bis-alloy 5 millimeters thick, each arm 13 having a length of 700 millimeters. A locating ear 14 helps locate the plate for assembly. A number of screw holes, such as at 15, are pre-drilled in the support beam to facilitate fixing. The roof sub-frames which are in a flange, are removably connected by the flange plate 16 shown in Figure 7. The flange plate is also made of bis-alloy 5 millimeters thick, and has a number of holes for screws, such as in 17. For the modular construction structure shown in Figure 5, the flange plate has arms of 400 millimeters 18, and a central region of 688 millimeters 19. The flange plate is formed with a plate reinforcement 20. For larger structures, an extension plate 21, as shown in Figure 8, facilitates the connection of the attached sub-frames to form a large roof or a tall building. Figure 9 shows the assembly of the wall sub-frames, the roof sub-frames, the supported beams, the extension plates, and the roof plates. A flange plate 22 is shown connecting to the roof sub-frames 23 and 24 which are in a flange. The attached roof sub-frames, such as at 25, will also be connected. In the example shown, each side of the roof is of two long sub-frames which therefore require the use of an extension plate 26 to join the roof sub-frames 27, 28, 29, and 30. The sub-frames of roof 28 and 27 extend beyond the wall sub-frames 31 and 32 to form the supported beams. The sub-frames 27, 28, 31 and 32 are connected with a supported beam 33. (The roof sub-frame 27 is shown short to reveal the supported beam 33). Although bis-alloy interconnect plates provide a high strength structure, they are not required in all situations. The interconnection plates can be made of light steel if the lower wind ratings are acceptable. An internal roof structure 34 can simply be added to the modular construction structure by screwing to, for example, the upper part of the wall eub-frame 31 and the supported beam 33.

All the sub-frames of the ceiling, the sub-frames of the wall and the interconnection plates are screwed together with screws M12 8.8 / S UNO. The assembly in Figure 9 can be easily disassembled by removing the screws. Other fasteners may be suitable, such as screws with expansion studs and welds in some situations. The modular construction structure is conveniently erected on a concrete slab 35 having hollow bolts 12 35a, as shown in Figure 10. The wall subframes 31 and 32 which are in a corner, are screwed to the slab of concrete and with each other as shown in Figure 9. Figure 11 illustrates a method of assembling a modular construction structure for a hut. A concrete slab is poured with cast screws. The corner wall sub-frames are initially screwed together and to the concrete foundation, as shown in Figure 11 (a). The remaining wall sub-frames are screwed to the concrete foundation as shown in Figure 11 (b). Conveniently, beams supported on their position can be screwed in this stage. A first roof sub-frame is erected in place, and the highest point can be supported with studs as shown in Figure 11 (c) or with the pinion fill (shown as 11 in Figure 5). The roof sub-frame is screwed to the supported beams. A corresponding roof sub-frame is erected, and it is screwed to the supported beams. A flange plate is screwed into position to connect the two roof sub-frames to form the floor shown in Figure 11 (d). The remaining roof sub-frames are screwed into place to finish the sub-frame of modular construction. The above describes a method to build a cabin. For other structures, the method of construction will vary. For example, an internal roof can be built on the assembled walls, before erecting the external roof sub-frames. In addition, the external roof could be assembled separately and lifted up to its position with a crane. The hut could be built directly on the ground without first pouring a slab. Due to the light weight of each subframe, the steps illustrated in Figure 11 to erect a sub-frame of modular construction, can be done by two people, although the task is a bit easier with three or more people. The invention is not limited to the simple structures of Figure 5 and Figure 11. A residential building is possible, such as the one shown in the separate view in parts of Figure 12. Figure 12 clearly shows a variety of different wall sub-frames, such as 36 and 37. The inner roof sub-frames 38 are also shown configured to form an internal roof. There is no requirement for internal ceiling reinforcement splints. The external roof sub-frames 39 are shown configured to form the roof of the house. There is no requirement for roof beams or roof reinforcement splints. The inventors have discovered that the roof structure is not required for the structural integrity of the construction structure. The internal roof sub-frames have sufficient structural capacity for a structure formed by wall sub-frames and internal ceiling sub-frames to comply with the relevant construction standards. This provides flexibility in construction, and facilitates having multi-story structures. In addition, the outer roof can be almost any shape without impacting the strength or wind resistance of the rest of the structure. It will be appreciated that any form of covering 40 can be used to cover the modular construction structure and finish the house. A common external roof covering would be the Custom Orb 0.42 B T. A common wall covering would be wood, fibrous sheet, or septum appearance. It will be appreciated that the structure illustrated in Figure 12 can be easily disassembled, and can be extended or relocated. The structure of the internal roof has sufficient load bearing capacity to form the floor or another floor. To form the extra floor it is only necessary to unscrew and remove the supported beams. Extension plates are screwed into place, the roof is lifted or removed, and the additional wall sub-frames are screwed into place. Then the joists are screwed in place to connect the sub-frames of the roof to the new wall sub-frames. In a similar way, the structure can be extended laterally. A wall or wall section is removed, and additional wall sub-frames are assembled to enlarge the structure. The internal ceiling sub-frames and the external roof sub-frames are assembled as described above. The invention has a particular advantage for forming structures in an unconventional manner. The octagonal hut 41 of Figure 13 would normally be constructed with a central pillar. With the modular construction structure described herein, the hut can be constructed without a central pillar. A custom flange plate 42, as shown in Figure 13, connects 8 roof sub-frames 43. The roof sub-frames 43 connect to the wall sub-frames in the same manner as described above. Figure 15 tabulates a variety of hatch structures that can be constructed with the three basic sub-frames described above. The table shows the material combinations required to achieve the required resistances (in Nm), and sample shed sizes. Column 44 applies to sub-frames C15019P / 2 (two perimeter members attached), and to 5-millimeter bis-alloy 360 interconnect plates. Column 45 applies to sub-frames C15019P, and to 5-millimeter bis-alloy 360 interconnect plates. Column 46 applies to sub-frames C15015, and to 5-millimeter bis-alloy 360 interconnect plates. Column 47 applies to sub-frames C15015, and 5 mm light steel interconnect plates. For example, a cabin 6 meters wide by 3 meters high constructed in accordance with the W55C wind evaluation, requires sub-frames C15015, and 5-mm bis-alloy 360 interconnect plate (column 46) or best. Similar tabulations can be prepared for other structures, such as a domestic room. In general, sub-frames C10015 are used for walls, or sub-frames C10015 or C15015 are used for internal ceilings, and sub-frames C15015 or C15019P are used for the external roof. It will be apparent to those skilled in the art of construction that the modular construction structure described herein offers a number of advantages. The open and rigid structure makes it possible to use a wide range of coating materials, which was not possible before. The coating can be erected on the structure by means of conventional elements. Because a standard range of sub-frames are prefabricated, there are significant advantages of better measurement tolerances and higher quality assurance. Structures with a wind rating from the lowest evaluation of W28N (NI) to the highest evaluation of W70C (C4), can be constructed using the same modular system. Due to the minimum number of components, to the lightweight sub-frames the layman or the professional builder, can easily erect a building in a minimum time. In practice, it has been found that the modular system according to the present invention makes it possible for the frame erection time to be reduced by at least 50 percent. This minimizes the impact of climate problems, and reduces the time to secure and complete the overall project. In addition, the height of the building can be increased at a later date by simply unscrewing and removing the external roof panels and support beams, fixing extra wall panels and interconnect plates on the top of existing wall panels, and replacing the support beams and roof panels. The system is also applicable for the design and construction of buildings having a variety of shapes, for example, hexagonal and octagonal, and in these cases, the panels of the roof structure will generally have a triangular configuration or other configuration. Throughout the descriptive memory, the objective has been to describe the preferred embodiments of the invention, without limiting the invention to any specific modality or collection of features.

Claims (23)

1. A modular construction structure comprising structural sub-frames and interconnection plates; being the structural sub-frames of an open construction, which have a previously determined configuration, and which are connected in a removable manner to form the structure of the building, including the walls and the ceiling, - where the wall sub-frames are they connect in a removable manner to form wall structures, the roof sub-frames are removably connected to the wall sub-frames by means of first interconnection plates, and the adjacent roof sub-frames which are on a flange , they are connected in a removable way by means of second interconnection plates, to form a roof structure, - the connection of the sub-frames with the sub-frames, and of the sub-frames with the interconnection plates, is by means of elements of removable fixation; the structure of modular construction can be constructed in multiple configurations; and wherein the structural integrity of the construction structure is provided by the interconnection sub-frames, without the need for coating or reinforcement.

2. The modular construction structure of claim 1, wherein the structural sub-frames comprise perimeter members and internal members.

3. The modular construction structure of claim 2, wherein the perimeter members provide structural integrity, and the internal members provide coating support.

4. The modular construction structure of claim 1, wherein the roof structure is provided by interconnected sub-frames without beams or reinforcements. The modular construction structure of claim 1, which further comprises an internal roof structure formed of interconnected sub-frames. The modular construction structure of claim 5, wherein the structural integrity of the construction structure is provided by the interconnected sub-frames that form the wall structures and the internal roof structure. The modular construction structure of claim i, wherein the structural sub-frames are assembled from materials having a high tensile strength, selected from the list including metal sections, fiber beams at carbon, synthetic wood, and plastic. The modular construction structure of claim 1, wherein the previously determined configuration of the structural sub-frames comprises a number of standard sizes and configurations. The modular construction structure of claim 8, wherein the sub-frames and the interconnection plates are previously manufactured. The modular construction structure of claim 1, wherein the connection of the wall sub-frames to the roof sub-frames by the first interconnection plates allows the formation of supported beams. The modular construction structure of claim 1, which further comprises third interconnecting plates, for releasably connecting one or more structural sub-frames that have a previously determined configuration to form sub-frames in combination. The modular construction structure of claim 1, which further comprises a third interconnect plate for removably connecting the standard sub-frames to form sub-frames in combination. The modular construction structure of claim 1, wherein the structural sub-frames are interconnected to form internal wall structures, internal roof structures, and external roof structures, without additional structural components. 14. The modular construction structure of claim 1, which further comprises a foundation on which the sub-frames are erected. 1

5. The modular construction structure of claim 14, where the foundation is a concrete foundation that has cast screws. 1

6. The modular construction structure of claim 15, wherein the concrete foundation is thickened at the edge, or adjusted with pillars. 1

7. A method for building a modular building having structural sub-frames and interconnection plates, which includes the steps of: prefabricating a plurality of structural sub-frames, including wall sub-frames and roof sub-frames, being these sub-frames of an open construction, and that have a previously determined configuration; connecting in a removable manner the adjacent wall sub-frames with the removable fixing elements to form wall structures; removably connect the roof sub-frames with the wall sub-frames, with the first interconnection plates and the removable fastening elements; removably connecting the adjacent sub-frames with the removable fastening elements, and the adjacent sub-frames being on a flange with second interconnection plates and removable fastening elements, to form a roof structure, not requiring this roof structure of beam members for their structural integrity; and removably joining the coating to the roof structure and wall structures, to form the modular building. The method of claim 17, wherein the step of removably connecting the adjacent roof sub-frames to form a roof structure includes the step of removably connecting the roof sub-frames that are found on a flange with second interconnection plates. The method of claim 17, which further includes the steps of removably connecting additional wall sub-frames with the wall structures, to form internal wall structures. The method of claim 17, which further includes the steps of prefabricating floor sub-frames, and removably connecting the floor sub-frames to form an internal floor structure. The method of claim 17, which further includes the steps of prefabricating inner roof sub-frames and removably connecting the inner roof sub-frames to form an internal roof structure, connecting these sub-frames to internal ceiling in a removable way with the wall sub-frames. 22. The method of claim 17, which further includes the step of removably connecting the sub-frames with the sub-frames, with third interconnection plates, to form larger structures. 23. A method for changing the configuration of a modular building having structural sub-frames and interconnecting plates, which includes the steps of: separating the covering of a modular building structure from the modular building; disconnect one or more sub-frames from the adjacent sub-frames and from one or more interconnection plates, removing the removable fasteners; connect additional sub-frames to the existing sub-frames, and one or more interconnection boards, to extend or modify the modular construction structure; reconnect the disconnected sub-frames and the interconnection plates with the removable fastening elements; and join the coating to finish the reconfigured modular building.