NO346454B1

NO346454B1 - A Construction Assembly for Building a Modular Structure

Info

Publication number: NO346454B1
Application number: NO20201443A
Authority: NO
Inventors: Håvar Moe
Original assignee: Moe Haavar
Priority date: 2020-12-30
Filing date: 2020-12-30
Publication date: 2022-08-22
Also published as: NO20201443A1

Description

A CONSTRUCTION ASSEMBLY FOR BUILDING A MODULAR STRUCTURE

The invention relates to a construction assembly for building a modular structure, and in particular to an assembly comprising box-shaped construction elements which are configured to be coupled together and assembled into a larger wall or building structure.

Although pre-fabricated buildings have been around for a long time, they have become much more important commercially over the past several decades, in particular for use as residential dwellings. The idea of “kit homes” has taken hold in a big way. This is perhaps partly as a result of the desire for more flexibility in terms of the design and location of a building, or the increasing importance placed in reducing the carbon footprint associated with manufacturing a building. It is also much easier to predict the cost of a project if modular construction techniques are used. The rate of development in this area has meant that it is now possible to order your home to arrive flat-packed as a kit of parts, from which a building can be constructed very quickly and very easily.

These pre-fabricated buildings are often formed of wood or similar environmentally friendly materials, and can come in the form of mobile homes (pre-constructed and moved to site), or modular homes brought to site as a number of box-like structures which will eventually form rooms. Alternatively, the structure can be shipped to site as panels, which are then joined together using adhesive, screws, or nails to hold the panels together to form wall elements and to couple these wall elements together. The latter option is the most efficient in terms of transport, and the rooms are then constructed on site by coupling together the panels to form walls that will eventually form a part of the building’s structure. EP-A-1387017 describes prefabricated wall elements for a building and hooked attachment mechanisms to be used for coupling the elements together. DE-A-1534746 relates to a similar mechanism, including two hooked portions, for joining solid wall elements together. SE-A-1150973 describes a modular building construction system including supporting frames for attachment to the floor and ceiling, and panels which are fixable to the frames. FR-A-2445871 relates to a system including a plurality of panels with grooves running down the side walls. Locking pins can be used to join two panels together via the grooves.

Means of improving the ease and efficiency with which modular buildings can be constructed are increasingly desirable.

According to a first aspect of the present invention, there is provided a construction assembly for building a modular structure, comprising: a first construction element having two side panels, a front panel, a back panel, and one or both of a top panel and a bottom panel, wherein at least one of the panels comprises at least one elongate aperture, the front and back panels of the first construction element are longer than the edge panels such that they form a skirt around a recess in the base of the element, and a set of holes or slits is provided in the skirt for the insertion of an axle through the front panel, across the recess, and through the back panel; and a coupling device comprising a first hooked portion for insertion through the at least one elongate aperture to grip the panel from behind, and a second hooked portion for insertion through the aperture in a panel of a second construction element of the same type to grip the panel of the second construction element from behind. A secure coupling is provided in which the coupling device is not visible once the two construction elements are fitted together and installed. This is a major advantage in the building trade in particular when constructing walls of a building.

A hooked portion in this context refers to a part of the coupling device that is shaped to extend around the edge of the aperture to some degree in order to prevent the coupling device from being removed through the aperture by a transverse movement, or by a movement perpendicular to the plane of the panel, once the coupling device has been inserted. The hooked portion may have an inner surface which is shaped to correspond to the edge of the aperture. A tight fit is provided between the coupling device and the aperture which can help to provide a wind and watertight seal and a more secure coupling between the first and second construction element.

In preferred embodiments, the coupling device is configured to grip the panel of the first construction element and the panel of the second construction element from behind such that the panels of the first and second construction elements are held against one another with the coupling device extending therebetween. The facing panels are touching and sit flat against one another. A tight fit is provided, and the coupling device is not visible from the outside leaving a smooth surface to the final modular structure.

In preferred embodiments, the second hooked portion includes a sloping surface which is oriented at an acute angle relative to the plane of the panel of the first construction element once the first hooked portion of the coupling device is inserted through the aperture of this panel to grip it from behind. When the construction elements are fitted together, the sloped surface can help to encourage the two elements into a tight fit.

In preferred embodiments, the sloping surface extends upwards towards a top panel of the first construction elements once the coupling device is inserted. The second construction element can therefore be dropped down into place, and will slide easily along the sloping surface to urge it sideways towards the first construction element under its own weight. This provides for a much easier installation requiring less physical strength.

In preferred embodiments, the construction assembly comprises the second construction element.

the combined thickness of the panels of the first and second construction elements is substantially equal to the distance between the base of the first and second hooked portions. This distance is equal to the sum of distances a and b in figure 6. The panels are therefore held tightly together once the coupling device is installed. In some examples, notches extend from the base of the hooked portions inwards and the panels sits side by side with the edges of adjacent apertures in each of the panels sitting comfortably in the notches.

In preferred embodiments, the coupling device comprises a notch at the base of the second hooked portion for fitting around an edge of an aperture in the panel of the second construction element once the coupling device is inserted therethrough. The width of the notch may therefore be the same as the thickness of the panel, at least in the region of the aperture. This will provide a tight fit for stability and potentially also some sealing capability.

In preferred embodiments, the panel of the first construction element is a side panel. In preferred embodiments, both side panels of the construction element are provided with the same number and configuration of apertures.

The front and back panels of the first construction element are longer than the edge panels such that they form a skirt around a recess in the base of the element and a set of holes or slits is provided in the skirt for the insertion of an axle through the front panel, across the recess, and through the back panel. Such axles are useful for installation and for providing wheels to allow easier transport of the construction elements around a building site.

In embodiments, a second set of holes or slits is provided in the skirt for insertion of a second axle through the front panel, across the recess, and through the back panel. The provision of two sets of wheels or two axles is particularly advantageous for easy installation and transport. The construction element, for example, does not need to be lifted while transporting and can sit stably on the four wheels without additional support.

In preferred embodiments, the construction assembly comprises a handle configured to be removably coupled to a construction element by insertion through the at least one elongate aperture on a panel of the construction element. In preferred embodiments, the handle comprises one or more protrusions configured to be inserted through the aperture to grip the panel from behind. The protrusions may be movable from a first position in which they can be inserted through the aperture to a second position in which they grip the panel from behind. The protrusions may be biased in the second position by a biasing mechanism, such as a spring. This handle further improves ease of transport, can be reused, and does not require additional fixings which may damage the construction elements.

In preferred embodiments, the panel comprises two or more elongated apertures which extend along a straight line to form a row of apertures in the panel. In preferred embodiments, the panel comprises two rows of elongated apertures extending along each of the two longest edges of the panel. This provides for a particularly secure coupling between the facing panels of the construction elements.

In preferred embodiments, the bottom edges of the front and back panels of the construction element form a skirt around a recess in its base and a set of holes or slits is provided in the skirt for the insertion of an axle through the front panel, across the recess, and through the back panel. In preferred embodiments, two sets of holes or slits are provided in the skirt at either end for insertion of two axles therethrough.

In preferred embodiments, the coupling device comprises a spine, and the first hooked portion and the second hooked portion are coupled to the spine, the first hooked portion each being configured to grip the panel of the first construction element from behind once it has been inserted through the aperture and the spine has been moved in the direction in which the aperture extends. This makes installation of the coupling device simpler and quicker, particularly if more than one aperture is used and the coupling device comprises more than one of each of the first and second hooked portions.

In preferred embodiments, the panel of the first construction element is a side panel comprising a plurality of elongated apertures and the coupling device comprises a corresponding number of first hooked portions. The coupling device may also comprise a corresponding number of second hooked portions. There are the same number of apertures in the plurality of apertures as there are first hooked portions (and possibly also second hooked portions). When the coupling device is coupled to the first construction element, each of the plurality of apertures has a hooked portion of the coupling device extending therethrough.

In preferred embodiments, the coupling device comprises a straight spine, the first and second hooked portions extend in opposite directions away from the spine, and the side panel comprises a groove along which the aperture or apertures extend and in which the spine sits when the first hooked portion of the coupling device is inserted through the aperture.

In preferred embodiments, the first hooked portions extend along the spine in a first direction, and the second hooked portions extend along the spine in the opposite direction. This provides for a particularly easy installation and allows that second construction element to be installed by lowering or dropping into engagement with the second hooked elements.

In preferred embodiments, the first and second hooked portions of each pair, extending on opposite sides of the spine, are offset from one another along the length of the spine. In embodiments, the offset distance corresponds to the length of the elongated aperture.

In preferred embodiments, the second hooked portion of the coupling device comprises a sloping surface oriented at an acute angle relative to the plane of the panel of the first construction element once the first hooked portion is inserted through the aperture.

In preferred embodiment, the panel of the first construction element is a side panel, and the sloping surface of the second hooked element extends away from the side panel and towards a top panel of the construction element once the coupling device is installed.

In preferred embodiments, the coupling device comprises a notched portion at the base of the second hooked portion for sealing or fitting around an edge of an aperture of the adjacent panel once the coupling device is inserted therethrough.

In preferred embodiments, the first and second hooked portions are identically shaped but extend in opposite directions relative to the spine.

There is described herein a coupling device comprising: a first hooked portion configured to for insertion through the at least one elongate aperture in a panel of a first construction element to grip the panel of the first construction element from behind, and a second hooked portion for insertion through an elongate aperture in a panel of a second construction element of the same type to grip the panel of the second construction element from behind such that the panels of the first and second construction elements are held against one another with the coupling device extending therebetween. In preferred examples, the coupling device is for coupling together elements of a modular structure, such as a wall, which may be the wall of a building.

According to a second aspect of the present invention, there is provided a method for assembling a modular structure, the method comprising: coupling a first construction element and a second construction element together, each construction element comprising two side panels, a front panel, a back panel, and one or both of a top panel and a bottom panel, wherein the bottom edges of the front and back panels of the second construction element are longer than the side panels such that they form a skirt having a set of holes or slits therein and a recess extending along its base, the method comprising: inserting a coupling device into an aperture in a panel of the first construction element so that a first hooked portion of the coupling device grips the panel from behind; inserting an axle through the set of holes or slits in the skirt to pass through the front panel, across the recess, and through the back panel; moving the second construction element towards the first construction element to insert a second hooked portion of the coupling device into an aperture in a panel of the second construction element and to position the second construction element over a base module, such that it is supported in a raised position by the axle; and allowing the second construction element to drop downwards, or lowering the second construction element, by pulling the axle out through the front or back panel until the upper edge of the aperture sits at the base of the second hooked portion so that the second hooked portion of the coupling device grips the panel of the second construction element from behind and the base module fits within the recess.

In preferred embodiments, wheels are provided at each end of the axle for transport of the construction element, and the method comprises removing at least one of the wheels prior to or at the same time as pulling the axle out through the front or back panel.

In preferred embodiments, the second construction element is provided with at least two wheels to allow it to be rolled into place.

According to a third aspect of the present invention, there is provided the use of a construction assembly according to the first aspect for building a modular structure. The modular structure may be a wall, for example the wall of a building.

According to an example, there is provided a method for manufacture of a construction element and coupling device, the method comprising: providing a first construction element and coupling device for assembly of a modular structure, the first construction element comprising two side panels, a front panel, and a back panel, a top panel, and a bottom panel; providing at least one elongate aperture in one of the panels; providing a coupling device comprising a first hooked portion for insertion through the at least one elongate aperture to grip the panel from behind, and a second hooked portion for insertion through the aperture in a panel of a second construction element of the same type to grip the panel of the second construction element from behind.

The invention will be described in more detail with reference to the figures in which:

Figure 1 is an exploded view of a construction element, including internal struts;

Figure 2 shows a construction element after assembly of the panels;

Figure 3A shows a side panel prior to assembly of a construction element;

Figure 3B shows a top panel or bottom panel prior to assembly of a construction element;

Figure 3C shows a front or back panel prior to assembly of a construction element;

Figure 4 shows a corner wall section formed of a number of construction elements, a base module, and a floor divider;

Figure 5 shows an assembled wall section surrounding a window;

Figure 6 shows a side view of a coupling device;

Figure 7A shows a part of a panel with coupling devices, one of which is inserted in an elongated aperture and another of which is not inserted;

Figure 7B shows the panel and coupling devices of figure 7A with the second coupling device partly inserted;

Figure 7C shows the panel and coupling devices of figures 7A and 7B with both coupling devices fully inserted in elongated apertures of the panel;

Figure 8A illustrates two construction elements of the same type, one of which has coupling devices inserted;

Figure 8B shows the construction elements and coupling devices of figure 8A as the second construction element is lowered down and slides along the upwards facing sloping surface of the coupling device;

Figure 8C shows the construction elements and coupling devices of figures 7A and 7B with the coupling devices fully attached, and the construction elements joined together;

Figure 9 is an exploded view of a possible corner wall structure including coupling devices;

Figure 10 shows a side view of a close up of a construction element with an alternative coupling device inserted;

Figure 11 shows a construction element with four wheels fitted;

Figure 12 illustrates a construction element placed above a base module, with axles inserted;

Figure 13A shows a first construction element and a second adjacent construction element with the coupling device partially inserted into the elongate aperture of the second construction element;

Figure 13B shows the two construction elements of figure 13A fully coupled after the axle has been removed, and the second construction element has been allowed to drop down into place along the upwards facing sloping surface of the coupling device;

Figure 14A illustrates a plan view of a removable handle;

Figure 14B shows the handle of figure 14A after insertion through the apertures of a construction element.

The construction elements described herein are generally provided in the form of box-shaped modules 28, which are able to be coupled together to form a larger structure. The larger structure may be a wall, and eventually a house or building, in which case the construction elements can be described as wall elements. These box-shaped modules may be formed of a light material such as a plywood. Any wood-based material is particularly suitable, and this may be in the form of laminate, MDF, or composite. In some cases, plastic or another material can be used instead or in addition. A mixture of different materials is also an option. The modular structure, resulting from the joining of several construction elements together, is strong and easy to construct, requiring the use of very few additional tools and parts. The elements are generally formed of a back panel 30, a front panel 32, two side panels 34, a bottom panel 36, and a top panel 38 (although either or both of the bottom or top plate may be omitted in some cases).

An exploded view of a construction element of this type is shown in figure 1. Each element in this case can also comprise internal struts 40 which extend in a longitudinal direction within the box-shaped structure formed by the panels. In the example shown, these extend between the bottom panel and the top panel, and also extend between the front and the back panels. In most cases, the element will be mounted with its longest side extending vertically, as shown in the figures, and so the internal struts can also be described as extending in a vertical direction or in an upwards direction. These form internal spaces which can be filled with hard or soft insulation after the construction element has been assembled into its box shape either at the building site or prior to transport. Filling with insulation can also be completed before fitting one or more of the panels, such as one of the front and back panels.

Generally, where a “vertical”, “horizontal”, “downwards” or “upwards” direction is described herein, this refers to the direction that will represent the vertical, horizontal, upwards, or downwards direction when the construction element or other part is mounted in place within the larger structure of which it will eventually form a part.

The vertically extending internal struts 40 are not load-bearing, and so can be formed as fairly thin structures, which minimises the heat transfer between the front and the back panels of the element. The load, which may be substantial if the element eventually forms part of a load bearing wall, is supported by at least the front and back panels. The front and back panels, and the top and bottom panels, may comprises slots 44 to allow the internal struts to be fitted in place without screws or additional parts. These can be seen in figures 2, 3B, and 3C extending in a longitudinal direction between the bottom and the top of a front/back panel and in a transverse direction across the top or bottom panel.

Figure 2 illustrates a construction element once the front, back, and side panels, the internal struts, and the top and bottom plates have been fitted together. Assembly of the element itself is facilitated by the shape of the panels and plates, which comprise a series of projections and notches 46 along their sides forming castellated edges. These may have 90° angles at their corners to form rectangular projections as shown in the figures. The protrusions or notches on the sides of each of the panels fit into corresponding recesses on the adjacent panels to form something similar to a dovetail joint. These notched edges are illustrated in figures 3A to 3C, which show a side plate, top or bottom plate (with a side view of the plate underneath), and front panel respectively.

The top and bottom panels may also fit into slots or grooves, which extend horizontally from side to side across the internal surface of the front and back panels at their upper and lower ends. In some cases, adhesive or similar may be applied to some or all of the abutting edges of the struts and panels prior to construction of the module to help to fix them in place and provide some additional support. Similar grooves may be provided on the internal surfaces of the side panels to help to retain the top and bottom panels.

One or more holes 48 may be provided through a panel of the element into each of the internal compartments in order to allow insulation to be pumped in to fill the element once it has been set in place. In figure 4, which shows several elements fixed together to form the start of a wall structure, these holes 48 are visible in the top panels of each of the construction elements 28. The holes are generally not closed off after the construction of a wall is complete, and these can therefore provide some ventilation to the inside of the element. If the internal parts of the element become damp for any reason, it is straightforward to remove the insulation by sucking through the holes for drying. This can then be reinserted into the construction element or replaced with new insulation. The holes may be provided anywhere on the element, and can be provided in more than one panel, but these will most usually extend through the top panel 38 only. This is advantageous in that insertion of the insulation once the element is in place is possible and the holes can be hidden by whatever structure is placed above (another construction element or a roof support, etc) and ensures that the insulation does not fall out during assembly of the modular structure.

The construction elements will usually comprise a downwards facing skirt 50 extending along both or one of the bottom front and back edges of the element. This skirt is formed by regions of the front and/or back panels which are extend down past the bottom panel to provide a recess 52, and may include slots or holes to be used for transport and installation, as will be described in more detail below. The front and back panels (32 and 30 respectively) are in this case longer than the side panels 34 so that the base panel coupled to the bottom of the side panels sits above the bottom of the front and back panels to form this recess 52. The recess can be used for mounting of the structure onto a base module 54. The base module 54 is an elongated structure which can sit on or be attached to the floor or ground to provide support for the wall, and may be formed in the same manner as the construction elements, or may simply represent a beam of wood or another material. In some cases, a similar skirt 50 can also be provided at the top of the element, also forming a recess for supporting an additional module, such as a floor divider 56. In figure 4, the floor divider 56 comprises a narrower region at the top and at the bottom over which the skirt of the adjacent construction elements can sit. This can help to provide a smooth and even surface to the resulting wall structure.

Figure 4 illustrates how several construction elements 28 may fit together to form the corner region of the wall of a two-storey building. The base modules 54 sit on the ground and may be firmly fixed thereto or to additional supporting structure or foundations. The base modules may extend along the entire length of the wall and will fit into the bottom recesses 52 of the construction elements forming the lower storey wall. The floor divider 56 sits within the top recess of the lower storey construction elements. An additional storey can then be placed on top of the floor divider by fitting this into the bottom recess of the upper storey construction elements. More than two storeys can be formed in this manner using additional floor dividers. Ceiling or floor structures may also be present, coupled to the floor dividers (not shown in figure 4). Usually the floor structure provided between storeys within a building will be set in place between constructing the upper and the lower storey, and can be used to aid with construction of the upper storey.

The base modules 54 and floor dividers 56 may be formed in a similar manner, and out of similar materials, to the construction elements 28 themselves. They may therefore include internal struts forming compartments into which insulation can be filled. The floor divider can, in some examples, include means for fixing onto an additional structure, such as a floor or ceiling, and one or more of the base module, floor dividers, and construction elements, can be provided with holes through the internal struts and side panels through which electrical wiring or pipes can be inserted. This greatly improves the ease with which a newly erected building can be fitted.

The construction elements 28 can be manufactured in standard sizes and shapes to suit different purposes. Some may be intended for use either as a simple wall section, and some can be shaped or sized for use in a region of the wall surrounding a window or a door, for example. Figure 5 illustrates some differently shaped construction elements used to assemble a section of wall including a window frame. Elements 1 and 3 are standard size wall sections and these will usually be supported on a base module (or directly on the floor or another support structure) either side of the window. The window is of the same width as a standard wall section, and the construction elements above and below the window opening 9 are of the same width, but are shorter in order to leave room for the window to be inserted. In order to install this structure, elements 1, 2, and 3 may initially be installed in place, for example by fitting them over a base module so that it sits within the recess 52 between the bottom parts of the front and back panels of each element. The elements will also be coupled to one another. The window frame portions 4, 5, and 6 are mounted, possibly in place of the top plate and side plates of the elements in the region surrounding the window. Construction element 7 is then placed between elements 1 and 3, and frame portion 8 is installed from below. If the coupling mechanism described below is used to couple adjacent modules, then construction elements may need to be installed in a different order to allow them to be dropped down into place (e.g. 1 and 2 fitted in place first, and then 7 and 3 fitted first together and then to parts 1 and 2 or first 1, then 7 and 2 separately, after which part 3 can be fitted to parts 7 and 2 to form the window).

Standard size construction elements may be between 100cm and 300cm in height, between 50cm and 150cm in width, and between 5cm and 30cm in depth. Elements may come in standard heights 120cm, 220cm, and 240cm, standard widths 120cm and 60cm, and standard depths 7cm, 10cm, 15cm, 20cm, and 21cm. Any combination of these standard measurements can be used. One standard sized element will be 120cm x 240cm x 21cm, for example, and another 60cm x 120cm x 15cm. The thickness of each of the panels may be between 5mm and 20mm, preferably between 10mm and 15mm, and preferably around 12mm. Of course, any size of construction element is possible, and these can be custom made to accommodate a particular building design. Because of the flat-pack nature of the parts forming the construction elements and the simple way in which these are assembled from the parts, elements can be manufactured as separate pieces and shipped in a very compact format before unpacking and assembling into the final box-shaped element on site.

The way in which adjacent construction elements 28 fit together is especially advantageous and allows construction of a building with minimal use of additional fixtures and tools. The mechanism uses no screws, which greatly reduces not only the complexity of the assembly process, but also the noise on site because no drills are required in order to fix construction elements within the same storey together. The surface of the wall once the construction elements are coupled together are also left smooth without any parts of the coupling devices being visible, and without screws or nails showing, which is of course a major benefit. This coupling mechanism works by the provision of one or more elongated apertures 58 in one or more of the panels of each construction element. These will usually be provided in the side panels, but a set of apertures can be provided in the front or back panel for coupling at a corner, for example. These may be provided in addition to or instead of apertures in the side panels to achieve the corner configuration shown in figure 4. The apertures 58 are shaped and sized to receive coupling devices 60 which can be inserted into the apertures to grip behind the panels of two adjacent construction elements to prevent them from being separated if force is applied to pull them apart. The apertures 58 and coupling devices 60 can be scaled both up and down according to need, with their relative shapes and sizes chosen to provide the interaction described above.

The apertures provided in the facing panels of the first and second construction elements will preferably be provided with a pattern of apertures which allows each pair of apertures to be collocated when the construction elements are fitted together. When placed side by side the facing panels will be provided with a pattern of apertures that are mirror images of one another. Each aperture on the panel of the first construction element will therefore have a corresponding aperture on the panel of the second construction element which will sit directly next to it in the same position, extending in the same direction, when the two panels sit side by side and the elements are coupled together. If the pattern is symmetrical, both panels may be provided with the same pattern of apertures. Panels can each be provided, for example, with one or more rows of apertures, with each of the apertures being slightly elongated and configured to receive a hooked portion of a coupling device. Each row may include between 1 and 10 apertures, preferably between 3 and 8 apertures, and most preferably between 4 and 6 apertures. The row or rows of apertures may extend in any direction across the panel (horizontally, diagonally) depending on what will be most convenient. Most often, each row will extend in a direction that will be vertical when the construction element is in place as part of a building structure, and will extend along one or more of the side panels.

The construction element 28 shown in figure 2, for example, is intended to be mounted so that it sits on top of a base module 54 or floor divider 56 with its longest side 62 extending vertically. It is preferable for the row of apertures to also extend vertically parallel with this longest side. This way the construction elements can be coupled together easily to form a wall shape, the weight of the element itself can be used to aid the installation process, as described below, and a larger number of coupling devices can be included for greater strength. Larger coupling devices with larger hooked portions can be used if required.

Although one row of apertures is sufficient, two rows running parallel to each other provides greater stability. The rows of apertures may run vertically, close to the long edges of the side panel as shown in figure 9. In a side panel of 21 cm width, the row of apertures may be located between 1cm and 5cm, preferably around 2cm from either edge (these edges corresponding to the edges of the box structure of the construction element when assembled).

An example of a coupling device for use in joining adjacent construction elements, and a method of assembly, is shown in figures 6, 7A-C, and 8A-C.

A side view of a particularly advantageous design for a coupling device 60 is shown in figure 6. This device will usually have a thickness (in a direction into the page in figure 6) of between 1mm and 10mm, preferably between 2mm and 6mm. The width of the apertures may correspond to the thickness of the coupling device so that the coupling devices fit tightly within the apertures and do not move from side to side. In the examples shown, the cross-sectional shape of the device in the thickness direction does not vary which makes it very simple to manufacture. The left half of the device comprises a first hooked portion 10 and notch 12 at the base of the first hooked portion. The right half of the device comprises a second hooked portion 14 and notch 16 at the base of the second hooked portion. The notches are each configured to have a width (shown as distance a and b respectively in the figure) equivalent to the thickness of the panel to which they are to be coupled. This way when the device is in place, it provides some sealing function because it sits tightly against the edge of the apertures on both adjacent construction elements with the facing panels of the construction elements touching and generally pressed together. The shape of notch 16, which includes a side wall 20 may also provide an improved gripping function to the panel of the second construction element. The distance between the base of the first hooked portion 10 where the panel edge will eventually sit and the region of the bottom surface directly below this (distance d marked in the figure) should be approximately equal the length of the aperture into which it is to be inserted, because the fit must be tight enough for the coupling device to remain in place during installation.

The base of notch 12 may include a horizontal portion 22 extending from the first hooked portion 10 followed by a downward sloping portion 24. The downward sloping portion allows the coupling device to be angled for insertion of the hooked portion 10 through the aperture (the step shown in figure 7B). At this point part of the upper edge of the aperture will sit on this sloping portion 24. Once the coupling device is twisted into place (as shown in figure 7C), another part of the same edge of the aperture will sit instead on the horizontal portion 22. The edge of the corresponding aperture in the second construction element will fit into notch 16 next to this, and will sit on the horizontal base 26 of this notch, so that the panels and the apertures are aligned with the coupling device extending between the two and providing a gripping function to hold the two facing panels together.

An additional extension can be provided along the bottom surface of the coupling device. This can sit just behind the bottom edge of the aperture, along the inside surface of the panel, once the device is inserted, to help to keep the device in place during installation. This extension or protrusion can be resilient material and designed to retract and extend so that the device can fit through the aperture initially with the protrusion retracted.

The coupling device can alternatively be designed with an additional lip along the lower surface as shown by the dotted lines in the figure, and can be inserted from behind during assembly of the construction element rather than inserting from the front and twisting as shown in figures 7A-7C. This way hooked portions are present both above and below the aperture once the device is in place within a first construction element. This design, however, has the disadvantage that it cannot be inserted once the construction element has been completely assembled, and so an interference fit, as shown in figures 7A-7C, will usually be preferable.

The coupling device 60, shown prior to insertion in figure 7A, is inserted by angling it, as shown in figure 7B, to direct the end of first hooked portion 10 through the aperture in the panel of the first construction element. The right part 24 of the base of notch 12 is angled relative to the base 26 of notch 16, and notch 16 includes a rightwards sloping edge 23, which allows this insertion of the element by tilting or angling to be achieved. At this point the panel wall forming the upper edge of the aperture fits into notch 16 with the base 26 of the notch flush against the aperture edge.

The right half of the device, including the second hooked portion 14, can then be twisted downwards until the back edge 18 of the first hooked portion 10 sits against the backside of the panel above the aperture as in figure 7C, gripping it. At this stage, the coupling device will fit tightly within the aperture because of the similar sizes of the aperture length and the height d of the coupling device where it passes through the aperture. This means that, once inserted, the coupling device cannot be easily removed and will be stably supported by an interference fit. Once the second panel is attached, as described below, the coupling device 60 and both panels will be secured in place.

The second hooked portion 14 also includes a notch 16, at its base, for receiving a panel of a second construction element. The upper surface of the second hooked portion is a sloping surface 64 which extends upwards at an angle α from a line X running parallel to the outer surface of the panel of the first construction element when the coupling device is installed. The hooked portion 14 may be angled between 10° and 80° with respect to this direction (X), more preferably between 30° and 60°, and will most preferably be angled around 45° to this direction. The fact that that the second hooked portion incudes an upwardly facing sloping surface 64 which is angled in this way means that the second construction element is actually pulled towards the first construction element as it drops down into place. The two construction elements do not therefore need to be pushed flush together before dropping the second construction element during the assembly process. The notched region 16 provides a recess in which the upper edge of an aperture of the second construction element can sit (and the notch may have a width roughly equal to the thickness of the panel). This helps to prevent the two construction elements from separating and may help a user to be able to judge when the second construction element is correctly fitted in place. The edge 20 of the second notch 16 may also be slightly sloped to ease movement of the second panel into position and to provide some play to accommodate panels which are slightly wider than the standard.

The process of attachment to a second construction element is shown in figures 8A-8C. In this case it is the second construction element which is moved to insert the second hooked portion 14 through an aperture. The second construction element to be attached is moved towards the first so that the apertures in the facing panel of the second construction element are aligned with uppermost portions of the hooked portions 14 (figure 8A). The second construction element is then pushed towards the first so that the hooked portion 14 is inserted partially into apertures on the second construction element (figure 8B). The second construction element is then allowed to drop down until the two construction elements are aligned vertically and both are fixed in place by the coupling device in between (figure 8C). No screws are required, and the weight of the second construction element as it drops down is utilised to make the assembly process easier.

The direction in which each elongated aperture extends, and so the direction in which the second construction element must be moved in order to fix it in place once the second hooked portion 14 is partially inserted, can be adapted. In some embodiments, the apertures can extend horizontally, and the second construction element is moved also horizontally to couple to the first construction element. A row of apertures extending in the same direction can be provided in some examples. It is preferable for there to be provided at least two apertures, one near to the top of the panel and one near to the bottom of the panel to better hold the construction elements in place. There may be between 1 and 20, preferably between 5 and 15 apertures, and most preferably between 8 and 12 apertures, in each panel. If one or more row of apertures is provided, spacings between the apertures in any particular row may be even spacings of between 5cm and 30cm.

The coupling device 60 may also be installed, in some examples, by insertion of a longer part through an elongated aperture and then a circular turning motion so that the same longer part of the coupling device sits behind the panel on either side of the aperture to provide the gripping function. In this case the aperture may extend at 90° to the direction in which the second construction element should in practice be moved or dropped in order to attach it to the coupling device. Usually, this will involve elongated apertures extending horizontally for a coupling device with a second hooked portion 14 that is still angled upwards one installed. The apertures on the facing panels of the first and second construction element may, in this case, not be identical, and may extend at 90° to one another.

The first hooked portion 10 can be any shape and size, so long as it can be inserted through one of the apertures in the side panel and, once inserted, cannot be removed by pulling directly away from the side panel (in a horizontal direction towards the front side of the panel). This means that a part of the hooked portion 10 must sit behind the panel wall above or below the aperture once inserted. There may also be an interference fit due to the length of the aperture matching a height of the coupling device at the point where it passes through the aperture once installed. Both effects may play a part in keeping the coupling device in place within the first construction element during assembly, as in the example shown in figure 6, but other mechanisms for holding the coupling device in place during assembly are conceivable (additional parts providing the interference fit, for example, or some type of temporary adhesive).

Another example of a coupling device is shown in figures 9 and 10. This device works (as in the case of the example shown in figure 6) by insertion through the elongated apertures and gripping behind the panels. These also include one or more hooked portions, which may be shaped similarly to the second hooked portion 14, or the right-hand portion, of the coupling device shown in figure 6, and which are configured to be inserted into the apertures provided in the panels to grip the panel from behind. However, rather than providing a separate coupling device for each aperture, the coupling device is integrated as a single piece which comprises a series of the hooks or hooked portions spaced along a central spine 66. Such an integrated coupling device may comprise hooked portions 68 spaced along the spine on either side. In addition to the apertures, the panels may comprise one or more grooves 70 along which the apertures are spaced in a row. The spine 66 of the coupling device sits comfortably in the groove 70 once installed, as shown in figure 10, with one set of hooked portions 68 extending through the apertures 58, and another set extending outwards of the panel for installation of a second construction element, as shown in figures 9 and 10.

The hooked portions 68 themselves extend both outwards from the spine 66 and in a direction along the spine. In the example shown, two sets of identical hooked portions are provided on either side of the spine, with one set of hooked portions extending in one direction along the spine and one set of hooked portions extending in the opposite direction along the spine. As can be seen most clearly in figure 10, one set of hooked portions are inserted into a row of apertures 58 in a first construction element leaving the second set free to receive a second construction element by insertion through a row of apertures on a panel of that construction element. In figures 9 and 10, the coupling device has already been inserted into the side panel of the first construction element by inserting each of the hooked portions through each of the apertures in a row such that the spine 66 sits at least partly within the groove 70 between the apertures 58 and then sliding the coupling device downwards so that downward extending portions of each of the hooked portions 58 sit behind the panel, offset from each the apertures. The coupling device cannot be removed by pulling horizontally and must first be lifted to align the downwardly extending portions of the hooked portions with the apertures again.

Although the hooked portions can be angled in the same sense (both upwards or both downwards) on either side of the spine, the preferred configuration will be to include hooked portions which extend in one direction (downwards) along the spine on one side and in the opposite direction (upwards) on the other. This way the coupling device can be fitted into place easily without additional means required to hold it in its offset position. Preferably the first hooked portions on one side of the spine which are angled downwards, and which are initially inserted into the first construction element, are offset along the length of the spine from the second hooked portions on the other side which are angled upwards. This offset means that a single design for positioning of the apertures is usable for all construction elements, as well as a single design for the coupling device. Reference to upwards and downwards is to the direction one way along the length of the spine and the other. This will correspond to the vertical direction where the coupling device is mounted vertically within the larger structure as in the example shown in figures 9 and 10.

The coupling device may therefore include a spine 66 on either side of which one or more hooked portions 68 are provided. The spacings between hooked portions along the spine is fixed to correspond to spacings between apertures 58 on one or more panels of one or more construction elements. The hooked portions are angled one way along the length of the spine on one side and the opposite way on the other (the shape of the hooked portion extending within the construction element is visible to the left in figure 10, and is angled downwards). The hooked portions may be angled between 10° and 80° with respect to a direction parallel with the spine, more preferably between 30° and 60°, and will most preferably be angled around 45° with respect to the spine 66.

In another example of an integrated coupling device the hooked portions attached along the spine comprise protrusion with a 90° bend, so that they extend first outwards (a first part) and then in a direction along the spine (a second part) with a 90° angle in between the two parts. Insertion through an aperture will therefore require a movement of the coupling device and panel towards one another so that the second part passes through the aperture, and then a movement of the coupling device upwards or downwards relative to the panel so that the second part sits behind a part of the panel adjacent to (above or below) the aperture. This type of hooked portion can also be inserted in some cases by a twisting or turning movement one the second part has been passed through the aperture, so that the second part extends at an angle to the direction in which the aperture extends once installed. The hooked portions 68 may also have different shapes to this.

Where grooves 70 are included, the spine 66 of the coupling device will sit partly within a groove in the panel of the first construction element, and partly within a groove in the panel of the second construction element, as can be seen in figures 9 and 10 where one half of the spine sits within the groove, so that once installed the facing side panels of the two construction elements are flush with each other and completely surround the coupling device. The coupling device will not therefore be visible once the two construction elements are joined together.

Figures 11 to 13 illustrate a method of installing and fitting a construction element within a modular structure which is particularly efficient. This method can be used with any of the different configurations of coupling devices and construction elements described above. The construction element in this case is provided with apertures or slots 72 at its base which allow an axle 74 and wheels 76 to be fitted. The or each axle can be passed through two holes or slits within the skirt 50 formed by the front and back panels of the construction element as shown. If one set of wheels is fitted, or one wheel is fitted on each axle, then the construction element may need to be supported to keep it upright during transport.

Generally, two sets of two wheels will be provided as shown in figure 11. If two or more sets of wheels are fitted, such as one at each end of the base of the construction element as shown, then the construction element can sit on the wheels in an upright position without additional support and can simply be pushed or pulled along. In this way, the construction element can be transported easily from a vehicle or from the place where it is assembled, to its final position, which may be quite some distance on a typical building site. The construction element may be able to be rolled on the wheels 76 almost to its final position. For the lower storeys, for example, the construction element will usually be mounted so that the skirt 50 sits over a base module 54 and the element can be rolled with the wheels 76 either side of the base module and into place. For the higher levels, floor structures which have been installed prior to assembly of the second storey construction elements allow the construction element still to be rolled into place over the floor divider or other structure on which it will eventually be supported. If this is not the case, and perhaps more often where external walls are being erected, some lifting may be required at the very end of the process.

Once it has been moved to the installation position using the wheels 76, the construction element sits above the structure on which it will eventually be supported. This may be a floor divider 56 or base module 54 of the type described above, which may in some cases simply represent a strip, beam, or structure which is configured to fit within the recesses 52 formed at the top and base of the construction elements. At this point, the construction element still has one or more axles 74 extending through the skirt 50 formed by the lower edges of the front and back panels and across the recess 52 therebetween (figure 11). One wheel on each of the axles is removed in the next stage, as has been done in figure 12. In order to be easily removable, the wheel may clip onto the axle with a snap-fit mechanism which allows it to be repeatedly set in place and removed again without damage to the wheel or axle. One or both of the wheels on each axle may be removable. One wheel may remain fixed, and the removable wheel can in this case be marked to indicate which can be taken off during installation.

The base module, floor divider, or other structure which will eventually sit within the recess formed by the skirt, is prevented from entering the recess by the axle 74 extending across the recess 52 from one side to the other, and the wall module is prevented from moving downwards into its final position. Two axles located near to the ends of the bottom panel are preferred, although more or fewer can be provided, since this allows the construction element to remain aligned with the structure which will eventually support it during this process. If wheels are not used to transport the construction element to its installation position, then an axle or rod (without wheels) can simply be inserted prior to setting the construction element above the base plate as shown in figures and used in the same manner as the axle with wheel fittings during the rest of the installation process. A handle may be provided on the rod or axle at one end to aid in pulling.

Next, as shown in figure 13A, the second construction element is pushed towards another, similar, first construction element which is already installed in its final position. If the construction elements are provided with the apertures and coupling devices such as those described above, the vertical position of axle 74 will be selected so that any coupling devices 60 which are already installed in the first construction element can be inserted into the apertures 58 in a panel of the second construction element during the coupling process. If the hooked portions of the coupling devices are shaped as shown in figure 6, the second construction element being installed does not need to be pushed at this stage so that it is flush with the adjacent element, but in some cases (such as if hooked portions with two parts oriented at 90° are used) this may be necessary.

The height of axle 74 is fixed by selecting the position of holes 72 or slits within the skirt of the construction element. The position and size of the holes or slits, as well as the size of the axle itself, may be selected so that when the axle is installed, the distance between the bottom of the axle on which the base module will sit during installation and the base panel of the construction element (or the top of the recess 52) is equal to or more than the height of the second hooked portion of the coupling device with which the construction element will eventually be coupled. This latter distance is shown as distance y in figure 6 in respect of the specific example shown, where it corresponds to the height of the second hooked portion above the base of the notch 16 in which the panel at the top of the aperture will eventually sit. This means that, provided that the length of the aperture 58 is sufficient, and the aperture is located so that it is coincident with the top of the hooked portion when the construction element sits on the axle, the construction element can drop by this same distance and into place with its bottom panel resting against the base module. The top edge of the aperture may also be at the same height or above the top of the coupling device’s hooked portion when the construction element sits on its axle, so that this can be inserted while the construction element is supported by the axles.

Once the construction element is in the correct horizontal position for coupling, and the second hooked portions of the coupling device extend at least partly into the apertures on the second construction element, the axle can be removed from the skirt by pulling on the axle itself or on a wheel or handle if present. The second construction element will then be able to drop down so that the skirt 50 sits over the structure 54 below, and the element will be moved into its coupled position over the second hooked portions of the coupling device, assisted by its own downwards motion. The two construction elements are now fixed together, and the axle and wheel can be applied to another element to continue the assembly process. The wheel may also be removed by pulling of the axle out through the skirt, rather than before, in which case it will fall off and drop down to be retrieved later.

The transport and assembly process can be further aided by use of a removable handle 78 which can be attached to the construction element. This can assist with pulling the construction element along on wheels 76 or lifting of the element. It is advantageous to provide a handle which can be used with the construction elements described above, which include apertures in at least one panel for a coupling device. The handle 78 can be provided with one or more protrusions or arms 80 which can be inserted through the same aperture or apertures 58 to grip behind the panel and hold the handle in place. The arms may be movable between a first position in which they can fit through the aperture and a second position in which at least a part of one or more arms sits behind the panel next to the aperture to hold the handle in place. The arms may be biased in the second position.

An example of a suitable handle for this purpose is shown in figures 14A and 14B. The handle includes a base 82, a handgrip 84, and arms 80 which have hooks 86 at their ends and which are spaced apart so as to be insertable into two adjacent elongate apertures of a construction element. The hooks 86 are coupled to the handgrip via the arms 80 which extend through openings 88 in the base 82 of the handle. The arms 80 and the hooks 86 are rotatable within the openings 88 to move them closer together and further apart. In this case the arms are coupled to discs or rings 90 which rotate about an axes along which the handgrip 84 also extends. The hooks 86 may be biased, using a spring or similar, into an open position shown in the figures where the arms 80 are positioned as far apart from one another as possible and abut the outer edges of the openings 88 in the base 82.

To insert the handle 78 into an elongate aperture 58 of a construction element, the handle is simply held so that the hooks 86 are aligned with each of two apertures. Pushing the handle towards the apertures results in sliding of the sloped edge 92 of the hooks 86 against the edge of the apertures and rotation of the arms 80 towards one another against the biasing force until the widest parts of the hooks have passed completely through the apertures. At this point the biasing force causes the arms to return to their open position with the hooks 86 sitting behind the panel surface adjacent the apertures 58 to hold the handle in place, as shown in figure 14B. The handle 78 can be removed by squeezing the arms 80 together to bring the hooks 86 back into alignment with the apertures 58, and then pulling the handle out by pulling the hooks out through the apertures.

The handle may include padding 94 on the arms where the edge of the construction element will sit once the handle is inserted. This prevents damage to the element itself and to the handle during transport. The handgrip 84 may also include a soft covering formed from foam, rubber, or a similar material in order to make it more comfortable to use and easier to grip. The handgrip 84 may be rotatable separately from the arms 80 but around the same axes, again to improve ease of use.

The handle 78 shown in the figures includes arms 80 and hooks 86 for fitting into two adjacent apertures, however only one set of hooks and arms can be included in some cases, and the handle can slot into one aperture only. In this case the spacing of the apertures on a panel will not affect whether the handle can be used. If two (or more) sets of hooks are to be used to fix the handle in place, different sizes of handles can be provided to correspond to standard aperture spacings on the standard sizes of construction elements. The spacing between the sets of hooks and/or the position of the arms in their open position can in some cases also be adjustable to allow the handle to fit to different sizes of construction element.

Although the construction elements are described herein as being configured for use as part of a wall structure in a building, and are particularly suited to this purpose, they can also be used for other means. The coupling mechanism can be used to join construction elements in order to produce any one of an artwork, a bookshelf, a table, a doll’s house, and a ceiling, to give a few examples.

Claims

1. A construction assembly for building a modular structure, comprising:

a first construction element (28) having two side panels (34), a front panel (32), a back panel (30), and one or both of a top panel (38) and a bottom panel (36), wherein at least one of the panels comprises at least one elongate aperture (58), the front and back panels of the first construction element are longer than the edge panels such that they form a skirt (50) around a recess (52) in the base of the element (28), and a set of holes (72) or slits is provided in the skirt (50) for the insertion of an axle (74) through the front panel (32), across the recess (52), and through the back panel (30); and

a coupling device (60) comprising a first hooked portion (10) for insertion through the at least one elongate aperture (58) to grip the panel of the first construction element from behind, and a second hooked portion (14) for insertion through an elongate aperture (58) in a panel of a second construction element of the same type to grip the panel of the second construction element from behind.

2. A construction assembly according to claim 1, wherein the coupling device (60) is configured to grip the panel of the first construction element and the panel of the second construction element from behind such that the panels of the first and second construction elements are held against one another with the coupling device extending therebetween.

3. A construction assembly according to any of claims 1 and 2, comprising the second construction element.

4. A construction assembly according to claim 3, wherein the combined thickness of the panels of the first and second construction elements is substantially equal to a distance between the base of the first (10) and second (14) hooked portions.

5. A construction assembly according to any of claims 1 to 4, wherein the second hooked portion (14) comprises a sloping surface (64) which is oriented at an acute angle relative to the plane of the panel of the first construction element once the first hooked portion (10) of the coupling device is inserted through the elongate aperture (58) of this panel to grip it from behind.

6. A construction assembly according to claim 5, wherein the sloping surface (64) extends upwards in a direction away from a bottom panel (36) of the first construction element once the coupling device (60) is inserted.

7. A construction assembly according to any of claims 1 to 6, wherein the coupling device (60) comprises a notch (16) at the base of the second hooked portion (14) for fitting around an edge of the elongate aperture (58) in the panel of the second construction element once the coupling device (60) is inserted therethrough.

8. A construction assembly according to any of claims 1 to 7, wherein the panel of the first construction element is a side panel (34).

9. A construction assembly according to any of claims 1 to 8, wherein a second set of holes or slits is provided in the skirt (50) for insertion of a second axle through the front panel (32), across the recess (52), and through the back panel (30).

10. A construction assembly according to any of claims 1 to 9, comprising a handle (78) configured to be removably coupled to a construction element (28) by insertion of part of the handle through the at least one elongate aperture (58) in the panel of the construction element.

11. A method for assembling a modular structure, the method comprising:

coupling a first construction element and a second construction element together, each construction element (28) comprising two side panels (34), a front panel (32), a back panel (30), and one or both of a top panel (38) and a bottom panel (36), wherein the bottom edges of the front and back panels of the second construction element are longer than the side panels such that they form a skirt (50) having a set of holes or slits therein and a recess (52) extending along its base, the method comprising:

inserting a coupling device (60) into an aperture (58) in a panel of the first construction element so that a first hooked portion (10) of the coupling device grips the panel from behind;

inserting an axle (74) through the set of holes or slits in the skirt (50) to pass through the front panel (32), across the recess (52), and through the back panel (30);

moving the second construction element towards the first construction element to insert a second hooked portion (14) of the coupling device into an aperture (58) in a panel of the second construction element and to position the second construction element over a base module (54), such that it is supported in a raised position by the axle; and

allowing the second construction element to drop downwards, or lowering the second construction element, by pulling the axle out through the front or back panel until the upper edge of the aperture sits at the base of the second hooked portion (14) so that the second hooked portion of the coupling device (60) grips the panel of the second construction element from behind and the base module fits within the recess.

12. A method according to claim 11, wherein wheels (76) are provided at each end of the axle (74) for transport of the construction element (28), and the method comprises removing at least one of the wheels (76) prior to or at the same time as pulling the axle (74) out through the front or back panel.

13. Use of a construction assembly according to any of claims 1 to 10 for building a modular structure.