BUILDING SYSTEM
This invention concerns a building construction according to the preamble of the patent claim 1.
The invention can be related to the building industry, especially prefabricated houses with prefabricated structural components which are mounted on site.
Today, prefabricated structural components are manufactured for detached or semi-detached houses in order to lower the costs and, for example, to enable a detached house to be built quickly. These structural components are manufactured somewhere other than on site. The structural components may for example be manufactured in a factory. On site, where the house is going to be erected, the prefabricated structural components are assembled into a detached or semi-detached house. The structural components are fitted to each other permanently with the aid of, for example, nails or other fixings.
Known technology suffers more generally from the fact that additional surface treatment including covering of the structural components has to take place on site, and that electrical wiring, water and sewage pipes, etc, must be installed on site. Known technology further suffers from the fact that the prefabricated structural components cannot be detached from each other without moving adjacent structural components, and that there has to be major interference in the structural component itself, and in the surface layer, because they are not technologically intended for fine-scale dismantling. Another disadvantage is that the customer for a detached or semi-detached house, according to known technology, is bound to a certain design of the house. The developer must therefore adjust to what today's market has to offer and to the price range in question. Should the customer be interested in a more personally designed house he or she will be obliged to resort to an architect-designed house which for the customer means great costs. Furthermore, the site is often adjusted to the prefabricated house, which means expensive blasting and landscaping work. Architect- designed houses are difficult and expensive to cost exactly and to design due to alternative executions and alternative layouts. Today prefabricated houses are burdened by the fact that the structural components are voluminous and difficult to handle, and that the site on which the house is to be erected, has to be adapted to the houses to an increasing high degree.
The above-mentioned problems are solved with the help of the invention according to the characterizing part of the patent claim 1 and according to the secondary claims accompanying the main claim.
Hereby the structural components can be easily fixed together without nails etc having to be used. The structural components can consequently also be easily connected to the framework of the house. That is to carriers or beams, roof trusses etc. The wall panels can according to the invention be connected to the corner posts and intermediate posts for the wall panels. The corner posts, intermediate posts and wall panels can be suitably positioned to produce external walls, which act as the facade of the house, and for dividing the rooms of the house.
The invention implies a considerably lower cost than today's prefabricated houses, and that applies to both new construction, rebuilding and extension.
Preferably, the locking bar of the coupling device can be pulled and pushed on at least one side edge perpendicular to the plane of the edge. Consequently a structural component can be freed from the other structural components without any major interference, such as moving adjacent structural components, pulling out nails, loosening fixings etc, being necessary. For assembly, the locking bar is pushed out of the structural component and consequently into a corresponding groove in an adjacent structural component by movement of the said coupling device to a inserted position, and is locked. This also facilitates dismantling of wall panels without moving adjacent structural components and thus allows excellent access for rebuilding, and extensions, and for technical modification of the building.
It is moreover advantageous that at least one of the side edges has its plane perpendicular to the sides of the structural component. This enables the side edges of the structural component to be fixed together giving a straight house wall with the aid of the said coupling device. The wall surfaces of the wall panels or sides are designated in this application as a first and a second side.
In the following the invention is schematically described with the help of an execution example where:
Fig 1. shows a view in perspective of the building construction according to the invention.
Fig 2. shows a closer detailed view than fig. 1, in perspective of the invention.
Fig 3. shows four exploded views in perspective of the structural component according to the invention.
Fig 4. shows an example of the coupling device according to the invention.
Fig 5. shows a view from above of several wall panels connected to the corner posts and the end members of the wall panels.
Fig 5a. shows a horizontal cross-section of several wall panels connected to intermediate posts and end members of the wall panels.
Fig. 6 shows a view in perspective of the building construction with electrical wiring and heating and sanitation installations.
In this application a first side and second side of the wall panels and the floor units are also referred to respectively as an inside and an outside seen from the inside of the house looking outwards.
Fig 1 shows schematically a view in perspective as an exploded view of the building construction according to the invention, where for a clear illustration of the invention, different structural components are separated from each other. It is shown that a framework 30 (columns 62, beams 6, roof trusses 7 etc) are for preference separately arranged from wall panel 10 and floor unit 9, 9a. In the specification of work, up or upwards means away from the ground "m" , and down and downwards means towards the ground "m". On rock, for example rock outcrops, prefabricated plinths 60 are advantageously placed. On these, beams 6 are mounted. Secondary beams 61 are mounted between beams 6. Supporting columns 62 are mounted on plinths 60. On the columns 62 it is advantageous to mount
climbing devices (not shown) so that hydraulic devices can lift up top structural components such as roof trusses 7 etc. To provide rain cover over the bottom floor structure at an early stage, the framework 30 (see above) and a roof 2 with roof covering (not shown) are first completed. A wind brace (not shown) of bracings and brackets is mounted to give stability to the partially erected house.
The floor units 9 are mounted and fixed on beams 6 according to the invention. These floor units 9 and ceiling panels 9a are connected to each other with the help of coupling device 18 (see fig. 3 and fig. 4) according to the invention. The coupling device 18 has at least one locking element which is profiled, locking bar 29 (see fig. 3, and fig. 4), which is pushed into a corresponding groove (see fig. 2) along the side edges 13, 14 in an adjacent structural component. In this way the floor units 9 and ceiling panels 9a are locked, and furthermore sealed by the seal 100, and levelled, and the relative positions of the structural components are precisely adjusted 101, 102 with locking bar 29 and coupling device 18. The floor units 9, 9a are locked and fixed in their position by attachments in the framework such as for example beams, roof trusses.
Now follows the work of connecting the remaining floor units 9 to each other. This is done in dry conditions under the already mounted roof 2. Then follows the mounting of the wall panels 10 according to the invention, and the floor units 9, which preferably includes prepared conduits and piping 34 and 38 (see fig. 6) which are preferably coupled to each other by levelling and precise adjustment of the position of the respective structural component (101 and 102) for electrical installations, or heating and sanitary installations through coupling device 18 and locking bar 29 for coupling devices 36 and 40.
This could be, for example, for bathroom 39, prepared draining gutters, coupling devices and piping for water and sewage. The wall panels 10 can advantageously contain prepared wiring 34 (see fig. 6) for future drawing of electric cables, telecommunication lines, etc, through re-lining. These conduits 34 have coupling devices 36 positioned at the side edges 13, 14 of the wall panels 10 and in grooves 1. The conduits 34 and piping 38 of the structural components, for electrical installations, and heating and sanitary installations respectively, are executed with re-lining.
Main and side ducts 65 (see fig. 6) for electrical installations and for heating and sanitary installations are then preferably mounted under the bottom floor structure 9. The floor units 9 are connected to each other by precision adjustment of the position of the respective structural component 101, 102 with locking bar 29 and coupling device 18 and thus also by precise adjustment of the coupling positions for the said pipes for electrical installations and heating and sanitary installations. Floor units 9 are preferably lifted hydraulically. On the prepared floor units 9 the ceiling panels 9a are connected to each other and are lifted, for example hydraulically, and then assembled and locked. The coupling device 18 with its locking elements (not shown in fig. 1) can preferably be designed similarly for, for example, both floor units 9, ceiling panels 9a and the wall panels 10. At least one locking bar 29 runs along the whole groove 1( see fig. 2).
Now the external walls are mounted according to the invention. The wall panels 10 are delivered to the site with the locking bars 29 (see fig. 3 and fig. 2) and are erected. Wall panels 10 are preferably connected to each other by inserting locking bar 29 in a corresponding groove 1 (see fig. 3 and fig. 2) in adjacent wall panel 10. The wall panels 10 are also connected to corner posts 4a, and intermediate posts 4b and to the end members 70 of the wall panels (see fig. 3, fig. 5, and fig. 5a) according to the invention. These corner posts 4a, intermediate posts 4b and end members 70 have a corresponding groove 1 for receiving the locking bars 29 of the wall panels 10. When connecting structural components 9, 9a, and 10 they are coupled with seal 100 and with precise adjustment of the positions of the structural components 101, 102 for, for example, coupling device 36, 40 by means of locking bar 29 and coupling device 18 (see fig. 3 and fig. 4). The finished conduits and piping 34 and 38 (see fig. 6) in the structural components 9, 9a, 10 are then re-lined on site with electrical wiring, hot + cold service water etc.
The corner and intermediate posts 4a and 4b and end members 70 can preferably form divisions between the rooms of the house according to the invention. These end members 70 can also be formed with an angle to produce a room with angles etc. As the locking bar 29 can be pushed out perpendicular to the side edges 13, 14 of the wall panel 10 a totally satisfactory connection can always be made with adjacent wall panel 10. A sealing device 100 (see fig. 5, fig. 5a, fig. 4 and fig. 1) is preferably executed between wall panels 10. Likewise at least one seal (100) is executed between floor units 9, 9a and between wall
panels 10 ( see fig. 3) and the bottom edge 15 and top edge 16a of the wall panels 10, and ground plate 3 and top piece 16 (see fig. 3 ).
The sealing device 100 can be in the shape of a rubber strip seal.
When walls are finished the wet groups such as sanitary porcelain etc can be installed. Finally the interior fittings and equipment in the house are installed.
According to the invention the wall panels 10 can for example be delivered to the building site with finished surface layers, for example wall paper (not shown) on the sides of the structural components facing into a habitable room etc. Only supplementary work on joints (not shown) of wall paper needs to be done when the wall panels 10 are on site, together with precise adjustment and levelling of the position 103 of structural components, with locking bar 29 and coupling device 18, for example for pattern alignment at the joints. The framework is erected first, after which structural components 9,9a, 10 are locked.
The floor units 9 are mounted on the framework 6 and the ceiling panels 9a are mounted on the framework, including roof trusses 7 (see figure 1). The ceiling panels 9a are mounted when the framework 6 is on site and before the wall panels 10, and comer and intermediate posts 4a, 4b, are mounted. The ground plates 3 are mounted on the floor units 9 and the top pieces 16 on the ceiling panel 9a (see fig. 3).
The wall panels 10 are intended for erecting or dismantling between ground plates 3 and top pieces 16. The top pieces 16 are provided with grooves 1, as shown in fig. 2, and fig. 3, where also the locking bar 29 with groove 1 on the lower edge 15 of the wall panels 10 is shown (fig. 3)
The locking of the wall panels in the vertical plane is achieved according to the invention by their being erected between ground plates 3 at the bottom and top pieces 16 at the top on the upper edge of the wall panels. Ground plates 3 and top pieces 16 are mounted on and attached to floor units 9 and ceiling panels 9a. The vertical locking of the wall panels is achieved by locking against ground plate 3 and top piece 16.
The lateral locking of the wall panels can be achieved in different ways. One way is for the locking bars 29 in the lower edge 15 and the upper edge 16a in the wall panels 10, to be locked in position on assembly so as to exert pressure on the ground plate 3 and the top
piece 16 perpendicular to the plane of the lower edge 15 and upper edge 16a . This results in friction on the contact surface created by upper edge 16a of the upper locking bar 29 and the groove 1 of top piece 16 and by respectively the lower edge 15 of the lower locking bar 29 and groove 1 of ground plate 3, locking the wall panel 10 sideways. A comparison may be made with the known method of wedging partitions between floor and roof. Corner and intermediate posts 4a and 4b and ground plate 3 and top piece 16 are permanently mounted on structural components 9 and 9a respectively. The lateral locking of the wall panels is also secured, except the friction described above, with corner posts 4a and intermediate posts 4b. Corner and intermediate posts 4a and 4b and ground plate 3 and top piece 16 are permanently mounted on the floor and ceiling components 9 and 9a respectively. Because the corner and intermediate posts 4a and 4b are connected to two wall panels 10 that are not orientated in the same plane, lateral displacement of one of the wall panels 10 is prevented because it is attached via corner and intermediate posts 4a and 4b, to the other wall panel 10, which is locked sideways. This locking should be clear from examination of fig. 5 and fig. 5a and a comprehensive consideration of the wall construction.
Fig. 2 shows a more detailed view in perspective than fig. 1 of the invention with the wall panels 10 and floor units 9, 9a schematically illustrated. As one can see the wall panels 10, the floor units 9, 9a and corner posts 4a, intermediate posts 4b, and middle pieces 4c are provided with grooves 1. At the connection of a structural component to another structural component or to a post 4a, 4b etc, locking bars 29 (see fig. 3) are moved with the help of a coupling device 18 (further described in fig. 4) into a corresponding groove 1 in adjacent structural component 9, 9a, 10 or for example corner post 4a, intermediate post 4b or middle piece 4c. Also locking bars 29 with seals 100, arranged for, for example, wall panels 10, are fitted into ground plate 3 and top piece 16, the ground plate 3 being mounted on the underlying floor units 9 and ceiling panels 9a.
Dismantling of, for example floor unit 9,9a, is preferable for more extensive rebuilding. For minor modifications the extra vacant conduits and pipes 34, 38 which have been inserted in suitable positions as a reserve at the factory, can advantageously be used for re-lining.
In the same way locking bars 29 and seals 100 in for example wall panels 10 are fitted into top pieces 16 on the top of the walls (see fig. 3). To enable a wall panel 10 or floor unit 9, 9a to be put into or taken out of the floor or wall after assembly, when all the structural
components are connected to each other, a structural component 9, 9a or 10 is provided with coupling devices on both side edges. In this way the locking bars 29 (see fig. 3, fig. 5, and fig. 5a) on both side edges of the structural component (this execution is described in figure 5 as structural component A and figure 5a as structural component B) can be pushed into the structural component according to the invention. The locking bar 29 applied to the coupling device 18, with the locking bar 29 when extended reaching into a groove 1 in the underlying ground plate 3, as well as into the top piece 16 (see fig. 3) is pushed with the aid of the coupling device 18 into the wall panel 10 when dismantling. In this way this structural component is completely released and is able to be moved between the other assembled structural components for, for example, dismantling.
When this is done remaining structural components can be detached from the others. It means, that the locking bar 29 (see fig. 3) in groove 1 of ground plate 3 and the locking bar 29 of one side edge are pushed in with the aid of the coupling device 18 (see fig. 3 ). A coupling device 18 can advantageously also be arranged on the upper edge 16a of wall panel 10 to lock with a top piece 16 above ( see fig.3). Fig. 2 also shows the building construction according to the invention with a framework 30 which is preferably arranged on the outside of the wall panels 10. The framework 30 consists of structural columns 62 and, mounted between these, beams 6 or secondary beams 61 and roof trusses 7 which bear floor units 9 and ceiling panels 9a respectively.
Fig. 3 shows a part of a view, in perspective, of the structural component 10,9,9a, according to the invention. The wall panel 10 has here been shown with two wall sections and one top and one bottom wall section showing ground plate 3 and top piece 16 respectively and with ten coupling devices 18 at an angle. The wall panel 10, according to the invention, has a first side 11, also called the front side, and a second side 12, also called the rear side, and two side edges 13, 14, a lower edge 15 and an upper edge 16a. In the figure the wall panel 10 has its coupling devices 18 on the one side edge 13, while the other side edge 14 is provided with a groove 1 for fitting of a corresponding locking bar (not shown) of an adjacent wall panel (not shown). The locking bar 29 at the wall panel 10 is in the figure inserted into the corresponding groove 1 of an adjacent wall panel 10 . Between two locking bars 29 with coupling devices 18 a pipe fitting 36, 40 (see fig. 6) is arranged. A conduit 34 (see fig. 6) for re-lining with electrical and telecommunication wiring through the wall panel 10 is installed in the structural component at the factory. When assembling the structural
components, according to the invention, on site the conduits 34 are coupled together through fitting 36, and are precisely adjusted by the position 101 of the respective structural component, by means of the locking bar 29 and the coupling device 18, and for example by the fact that the conduit of one wall panel is of bigger dimensions at the coupling position than the other, and preferably by fine adjustment of the position of the structural components 101, 102, by means of locking bar 29 and locking device 18. Precise adjustment of the relative position 103 of structural components can preferably be achieved in conjunction with pattern adjustment of the surface layer. The lower edge 15 and the upper edge 16a are preferably provided with locking bars 29 and locking devices similar to those at the side edges (see fig. 3). The locking device ensures in a simple manner that the locking bar is locked in its projecting position.
The wall sections at the bottom and at the top show how locking bar 29 with the aid of coupling device 18 is pushed into groove 1 in ground plate 3 and top piece 16. Under the ground plate and over the top piece are shown a middle piece 4c with groove 1 that preferably allows adjacent floor unit 9, or 9a, to be easily detached from adjacent floor unit 9, or ceiling panel 9a, according to the invention, for, for example, dismantling or assembly.
Fig. 4 shows a view of a connection between structural component 10 and 9,9a, and an example of coupling device 18 according to the invention, where a section shows a gear rack 80 arranged to be pushed with the aid of trunnion 81. The trunnion 81 can on its suspended end, for example on the inside of the wall 11, be provided with a wheel (not shown) The gear rack 80 and the trunnion 81 are preferably journalled in bearings (not shown). When the trunnion 81 is turned in the direction shown by the arrow p, the gear rack 80 is led into the structural component. The locking bar 29 is coupled to one end of the gear rack 80. Accordingly the locking bar 29 is also led into a suitable groove 1 in the structural component. Seals 100 of, for example, rubber are preferably arranged between the side edges 13,14 of the structural components 9,9a, 10, on the locking bar 29 and at the grooves 1 against the side edges of the structural components and against the upper edge 16a and lower edge 15 of the structural components, and at the grooves 1.
Fig. 5 shows a horizontal section (a view from above of several wall panels 10) connected to each other to form comers through comer post 4a. The figure shows a view from above of three wall panels 10. The end members 70 of the wall panels 10 join two wall panels 10a and 10b at an angle. Because the locking bar 29 can be pushed at right angles to the plane of
the side edges 13, 14, a number of different angles can be obtained at co er post 4a or intermediate post 4b. Differently angled posts can be used as required. The end member 70 of the wall panel 10a, 10b, in the figure is angled approximately 10 degrees. The comer post 4a makes a 90-degree comer. It is clearly shown in the figure, as well as in fig. 3, fig. 4, and fig. 5a how the locking bars 29 can be pushed into a corresponding groove 1 in the end members 70, and into the posts 4a and 4b. The structural component shown at A is preferably provided with locking devices 18, arranged on both side edges, so that the structural component A can be simply released from the wall and the wall panels 10 according to the invention for, for example, dismantling or assembly.
Fig. 5a shows a horizontal section of wall panels 10 connected to each other at intermediate post 4b. The structural component B is preferably provided with locking devices 18 on both side edges to enable the structural component B to be simply released from wall panels 10 according to the invention for, for example, dismantling or assembly. Comer posts and intermediate posts 4a and 4b, and middle pieces 4c can preferably be provided with prepared grooves 8 for future connection of wall and floor unit 17 for, for example, rebuilding or extension.
For major rebuilding with extensive new heating and sanitary installations floor units 9, 9a can preferably be dismantled according to the invention (fig. 2, fig. 3) and new floor units can be fitted.
For minor modifications empty conduits and pipes 34, 38, previously installed at the factory, can preferably be used and re-lined on site and be provided with fittings 36 and 40.
Fig. 6 shows a view in perspective of the building construction with the electrical and heating and sanitary installations. The figure shows a building construction in cross section, according to the invention. It is clearly shown how the sanitary appliances 110 are installed. These are connected to the re-lined heating and sanitary installations. The pre-installed vacant pipes 38 which are arranged in the floor units 9 connect to a pipe duct 65 that is situated in the centre under the floor structure and to coupling devices 40 that can be reached by inspection covers.
Fixed internal fittings 116 are in the figure also mounted on site.
Re-lining of electrical and heating and sanitary installations and of installations for telecommunication etc takes place on site. Bushings for the wires are achieved by means of re-lining (not shown). The wires are bushed on site through preinstalled empty conduits and pipes 34, 38, which at the coupling of structural components 10, 9, 9a with coupling device 18 and locking bar 29, with precision adjustment and fixing of the position of the structural components, for electrical and heating and sanitary installations 101 and 102 respectively, are coupled to each other at the couplings 36, 40. Junction boxes etc are then connected to the re-lined pipes.
With the aid of a computer program the different building components can be fitted into a model, which can be presented on a computer screen. At the same time the computer program can calculate the cost of the house. Since the position of every coupling device with its locking bar 29 corresponds with the position of the groove 1 on the adjacent structural component, the different structural components can be fitted and precisely adjusted through coupling device 18 and locking bar 29 and to each other. The position of the coupling devices 18 can however be described in the computer program, which will make the planning of the erection of the house easier.
For example a CAD-program or CAD-CAM can be used together with a calculation program, which gives an immediate answer to what alternative layouts, choices of materials etc, cost. In the CAD-program, for example, a large assortment of different structural components and materials in a number of colours is included. Through the CAD-technology the client can make a personal choice of materials and colourings. The mounting and painting at the factory gives considerably lower costs than surface treatment on site. The structural components can preferably be painted by the help of a CAD/CAM application.
The house construction can preferably be completed with a facade (not shown). For example with technological additions or to give a personal character to the house, such as solar protection, personal decoration etc, with the facade (not shown) including structural components with coupling device 18 and locking bar 29 according to the invention.
As all exterior and interior walls are arranged independently of the framework 30, the erection and removal of external walls 200 and interior walls 300 can take place without interfering with the framework 30 in any rebuilding work. After removal of the desired
external walls and if applicable interior walls, the framework 30 can be dismantled. When assembling or dismantling the parts of framework 30 or floor structure 9 etc climbing devices can preferably be used for erecting roof trusses 7 etc. This can be done by using for example light, hydraulic aids (not shown).
To give a personal character to the facade different arrangements of supplementary fasade, such as, slats, supplementary windows with glazing bars, which include a coupling device with locking bar 29 and coupling device 18 according to the invention, can be coupled together as required. A sunroof with similar coupling device 18 and locking bar 29 to those of wall and floor panels, can be fitted or removed as required..