WO2010142032A1

WO2010142032A1 - Modular construction system

Info

Publication number: WO2010142032A1
Application number: PCT/CA2010/000878
Authority: WO
Inventors: Jean-Robert Tremblay
Original assignee: Concept Polyghome Inc.
Priority date: 2009-06-10
Filing date: 2010-06-10
Publication date: 2010-12-16

Abstract

A modular construction system for constructing a building which includes a plurality of frame units and a plurality of posts for mounting the frame units one above another so as to construct at least one modular block unit. Each frame unit has a trapezoidal shape and includes a pair of opposed unparallel primary girders of equal length, and a pair of opposed parallel secondary girders of different lengths, which interconnect the primary girders.

Description

MODULAR CONSTRUCTION SYSTEM

FIELD OF THE INVENTION

The present invention relates to construction systems. More particularly, it concerns a modular construction system for constructing a building.

BACKGROUND OF THE INVENTION

Conventional modular construction systems typically form rectangular building units which can be assembled from a kit of components and joined to similar building units in order to create a larger structure.

Modularly constructed buildings are advantageous in that they simplify the design and construction process. An example of such a conventional construction system is described in Canadian patent application no. 2,603,021 (Tremblay).

However, it has been found that such conventional construction systems comprising right-angled building units restrict the design of buildings having more complex shapes which may be desirable for many reasons, including for esthetic purposes, due to constraints imposed by the building site, or indeed for improved aerodynamic characteristics.

As such, there remains a need for an improved modular construction system which addresses at least some of the abovementioned shortcomings.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a modular construction system that addresses at least partially the aforementioned need.

According to an aspect of the present invention that object is achieved with a modular construction system for constructing a building. The system includes a plurality of frame units and a plurality of posts for mounting the frame units one above another so as to construct at least one modular block unit. Each frame unit has a trapezoidal shape and includes a pair of opposed unparallel primary girders of equal length, and a pair of opposed parallel secondary girders of different lengths, which interconnect the primary girders.

As used herein, the expression "modular construction system" should be understood as a construction system designed with standardized base units for easy assembly and flexible arrangement and use.

As used herein, the expression "girder" should be understood as a horizontal beam used as a main support for a building and especially one which can support other beams.

As used herein, the expression "post" should be understood as a vertical beam used as a main support for a building.

It will be appreciated that the phrase "equal length" is used herein insofar as it pertains to the trapezoidal shape and the length of the primary girders which extend between their interconnections with the secondary girders. It will be appreciated that one of a given pair of primary girders may, for example, extend beyond a secondary girder while the other does not, all the while maintaining the desired trapezoidal shape. In such a case it will be appreciated that the effective lengths of these two primary girders are in fact equal, despite the fact that one includes additional extensions. Such primary girders should therefore be understood as within the scope of the present invention.

Similarly, the phrase "different lengths" as used herein refers to the lengths of the secondary girders which extend between their interconnections with the primary girders and is not affected by any additional portions which extend beyond those interconnections. It will be appreciated that a modular construction system according to the present invention may advantageously enable the design and rapid construction of more esthetically pleasing buildings, and more versatile building shapes. As it will be explained herein below it further allows the construction of buildings with improved aerodynamic characteristics, with an optimization of the use of the available surface area and view.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects, advantages and features of the present invention will become more apparent upon reading of the following non-restrictive description of preferred embodiments thereof, given for the purpose of exemplification only, with reference to the accompanying drawings in which:

FIGs. 1a and 1b are a rear perspective view and a top view, respectively, of a modular construction system in accordance with a preferred embodiment of the present invention;

FIG. 2 is a front perspective view of the system of FIGs. 1a and 1 b, without the upper modular block unit and with the addition of a floor and transverse walls;

FIG. 3a is a side view of the system of FIGs. 1a and 1b, with the addition of floors, transverse walls and a roof;

FIG. 3b is a cross-sectional view taken along line 3b-3b in FIG. 1 b;

FIG. 4 is an enlarged fragmentary perspective view of the cross-section taken along line 4-4 in FIG. 3a;

FIG. 5 is an enlarged fragmentary perspective view of the cross-section taken along line 5-5 in FIG. 3a; FIG. 6 is an enlarged fragmentary perspective view of the cross-section taken along line 6-6 in FIG. 1b;

FIGs. 6 and 7 are two different enlarged fragmentary perspective views of the cross- section taken along line 6-6 in FIG. 1 b;

FIG. 8 is an enlarged fragmentary perspective view of the front of the system of the previous figures;

FIGs. 9a and 9b are top and perspective views, respectively, of a footing in accordance with an embodiment of the present invention;

FIGs. 10a and 10b are schematic representations of various arrangements of frame units and posts in accordance with the present invention;

FIG. 11 is a perspective view of a building constructed with system in accordance with an embodiment of the present invention; and

FIGs. 12a and 12b are a rear perspective and top view, respectively, of a modular construction system in accordance with another embodiment of the present invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

In the following description, similar features in the drawings have been given similar reference numerals and in order to lighten the figures, some elements are not referred to in some figures if they were already identified in a previous figure.

It will be understood that positional expressions such as "front", "rear" and the like as used herein are meant relative to the specific view or views shown in the drawings and are not, unless otherwise indicated, meant to be interpreted in a limiting manner. Similarly, expressions such as "top", "bottom", "upper", "lower", "underside" and "topside" are also meant relative to the specific view or views shown in the drawings.

List of numerical references and corresponding preferred components illustrated:

10 construction system

12 first frame unit

14 second frame unit 16 third frame unit

18 house posts

20 modular block unit

22 foundation

24 footings 28 primary girder

30 secondary girder

32 secondary girder

34 transverse joist

36 longitudinal joist 38 floor

40 floor panel

42 rear vertical wall

44 front vertical wall

46 transverse frame 48 panels

50 lower wall

52 rod

54 roof

56 roof panels 58 ceiling

60 bracket

62 screws 64 channel

66 hole (girder)

68 hole (post)

70 bolt 72 box

74 opening (secondary girder)

76 opening (frame)

78 base

80 rim 82 void

84 slot

86 rear side

88 front side

90 upper side 92 side wall

94 brackets

100 building structure

FIGs. 1 a and 1 b show a modular construction system 10 for constructing a building from a plurality of frame units 12, 14 and 16, and a plurality of posts 18. The frame units 12, 14 and 16 and posts 18 are assembled so as to form two modular block units 20a and 20b, one level mounted above the other. As will be discussed herein below, a plurality of modular block units 20 can be assembled vertically and/or side- by-side.

The lower modular block unit 20a is formed by a first frame unit 12, a second frame unit 14 and a plurality of vertical posts 18 mounted therebetween. The upper modular block unit 20b is similarly formed by the second and third frame units 14 and 16, which are separated by another set of posts 18. In use, the first frame unit 12 can support a floor, the second frame unit 16 can support a ceiling and floor thereabove, and the third frame unit 18 can support a ceiling and a roof, as will be discussed further herein below. Each frame unit 12, 14 and 16 comprises a trapezoidal shape formed by a first pair of longitudinally extending primary girders 28 and a pair of transversally extending secondary girders 30 and 32. In order to achieve the trapezoidal shape, the primary girders 28 are of equal length, and oriented at an angle to the centerline of the modular block unit 20, as best seen in FIG. 1 b. The secondary girders 30 and 32, which interconnect the primary girders 28, are parallel and of different lengths.

In the present configuration, the shorter secondary girder 30 is at the rear of the structure, while the longer secondary girder 32 is at the front. Preferably, the girders 28, 30 and 32 are formed from a wood product. Preferably, the posts 18 taper upwards, that is to say they increase in cross section as they extend upwards.

As seen in FIG. 1a, the posts 18 can be of varying lengths in order to provide, for example, a sloping roof. Specifically, the front posts 18 of the upper modular block unit 20b are longer than the posts 18 of the remainder of the structure. As such, the roof supported by the third frame unit 16 will slope downward from front to rear. However, as seen in FIG. 1 b the frame units 12, 14 and 16 all have the same trapezoidal projection when viewed from above. Accordingly, the primary girders 28 of the upper frame unit 16 will be longer than the other primary girders 28. As such, the trapezoidal shapes of each frame unit 12, 14 and 16 can be said to correspond to one another even when some of the primary girders 28 are longer or shorter than the others.

The lower modular block unit 20a is constructed upon a foundation 22. Preferably, the foundation 22 comprises a plurality of footings 24 which are fixed at each corner of the first frame unit 12 and at points approximately midway along the longitudinal primary girders 28. It will be appreciated that such footings 24 avoid the need for a poured concrete foundation and the wall boarding associated therewith.

Moreover, mounting the footings 24 in the manner illustrated creates a space between the underside of first frame unit 12 and the ground therebelow which may advantageously be used to circulate air for heating the floor. This space may also be used to isolate unwanted gases which may permeate from the ground.

It will also be appreciated that various other types of foundations 22 could similarly be used.

As is known in the art, joists may be provided across the frame units 12, 14 and/or 16 in order to strengthen the structure. In the embodiment illustrated, the first and second frame units 12 and 14 are provided with a transverse joist 34 which extends from the midpoint of one primary girder 28 to the midpoint of the other. A longitudinal joist 36 is also provided extending between the front secondary girder 32 and the transverse joist 34, along the centerline of the frame units 12 and 14. These joists 34 and 36 serve primarily to provide additional reinforcement for the surface installed thereabove, such as a floor. Given that the third frame unit 16 is intended to support a roof, it may not require such joists 34 and 36.

It will be appreciated various other arrangements of transverse and/or longitudinal joists 34 and 36 could also be provided. For example, a plurality of transverse joists 34 could be provided in parallel, each extending between primary girders 28 of a given frame unit 12, 14 or 16.

Preferably, and as illustrated, the primary girders 28 are 23 feet in length while the rear and front secondary girders 30 and 32 are 4 feet 9 inches and 10 feet 11 inches in length, respectively. Each modular block unit 20 is symmetrical about its centerline and the primary girders 28 sweep out an arc of 15°.

In FIG. 2, the lower modular block unit 20a of the previous figures is shown with the addition of a floor 38 installed atop the first frame unit 12, making the first frame unit 12 a floor frame unit 12. Preferably, the floor 38 is formed by a plurality of floor panels 40. The floor panels 40 extend transversally across the primary girders 28. Preferably, the floor panels 40 are 54 mm thick wooden planks. In addition, a rear wall 42 extends vertically and transversally between the rear secondary girders 30 (only the upper of which is shown) and the adjacent posts 18, while a front wall 44 similarly extends vertically and transversally between the front secondary girders 32 (only the upper of which is shown). The rear wall 42 is an opaque wall, preferably comprising an insulating layer. The front wall 44 forms a transverse frame 46 able to receive a plurality of panels 48. These panels 48 can be transparent window panels, as illustrated, or may alternatively be provided as opaque panels. In one embodiment, the structure is provided with solar panels 48 across some or all of the transverse frame 46 for providing solar thermal heating and/or photovoltaic energy generation. Preferably, the transverse frame 46 is formed from extruded aluminum or plastic. It will be appreciated that similar panels 48 could be provided at the rear of the modular block unit 20a, while an insulating wall could similarly be provided at the front.

As shown, portions of the primary girders 28 extend slightly beyond the secondary girders 30 and 32. It will be appreciated however that he reverse could similarly be true, or indeed that additional sections of the longitudinal girders 28 could be added which extend well beyond the rear secondary girder 30 and/or the front secondary girder 32.

Preferably, a lower insulation wall 50 is provided between the lower front secondary girder 32 (not shown) and the adjacent front footings 24. This wall will aid in isolating and insulating the space below the floor 38 and the first frame unit 12. When properly isolated, this space can then be heated, as will be discussed in further detail herein below.

Also shown in FIG. 2 is a plurality of rods 52, portions of which extend upward from the second frame unit 14. Preferably, four rods 52 are provided at or near the junction between the primary and secondary girders 28, 30 and 32, as will be discussed in further detail herein below.

Referring now to FIG. 3a, a side view of the modular block units 20a and 20b is shown. In contrast with FIGs. 1a and 1 b, floors 38 made of floor panels 40 have been provided above the first and second frame units 12 and 14 and a roof 54 made of roof panels 56 has been provided above the third frame unit 16, making the third frame unit 16 a roof frame unit 16. Preferably, the roof panels 56 are 54 mm thick wooden planks with a urethane coating. The roof panels 56 may comprise a sheet of insulation therewithin,

As will be apparent to one of ordinary skill in the art, various other structures or layers could be subsequently installed on the roof 16, such as roof tiles, cornices, drains and other functional and/or decorative elements.

FIG. 3b shows a similar view as FIG. 3a but this time showing the structure in cross- section, thereby exposing the joists 34 and 36, the rear and front vertical walls 42 and 44 installed between the first and second frame units 12 and 14, as well as those installed between the second and third frame units 14 and 16. Additionally shown are two ceilings 58 hung from the second and third frame units 14 and 16, the formed positioned opposite the floor panels 40 and the latter positioned opposite the roof panels 56. These ceilings 58 can be made from a variety of materials including but not limited to drywall, wooden panels or vinyl panels, and can be primarily aesthetic in function or, more preferably, to create another space within each frame unit 14 and 16 in which to install insulation or circulate heating/cooling air.

With reference now to FIG. 4, the front left corner of the second frame unit 14 is shown in cross-section, where the secondary girder 32 meets the primary girder 28.

These two elements are joined by a bracket 60 via screws 62. Preferably, the bracket 60 extends beyond the front edge of the primary girder so as to provide mounting points for an external, protective and/or decorative layer. Preferably, the brackets 60 are made of steel. It will be appreciated that various other arrangements for interconnecting the girders 28, 30 and 32 are also within the scope of the present invention. In addition, one of the rods 52 is shown extending vertically within a hole 66 in the primary girder 28. Preferably, the rod 52 is a hollow tube, although it will be appreciated that differently shaped elongate members may similarly be used.

With additional reference to FIG. 5, a similar cross-section is shown, taken just above that of FIG. 4. In this view the rod 52 is similarly shown extending vertically within a hole 68 in the upper post 18. The transverse frame unit 46 preferably comprises a channel 64 therewithin which extends vertically alongside the post 18. Similar channels 64 may also extend horizontally across the frame unit 46 as well. Such channels 64 can be used to convey heating or cooling air.

With additional reference to FIG. 6, another cross-section of the front left corner of the second frame unit 14 is shown, although in this case it is taken vertically through the primary girder 28. In addition to the rod 52 shown in FIG. 2 which extends upwards from the primary girder 28, another rod 52 is provided extending downwards therefrom. Preferably, the hole 66 extends all the way through the primary girder 28. The rods 52 are held in place by horizontally disposed bolts 70. It will be appreciated however that a single rod 52 having twice the length and able to pass through the primary girder 28 and into the upper and lower posts 18 could similarly be provided.

FIG. 7 shows a similar cross-section to that in FIG. 6, although in this case focused on the mounting of the first frame unit 12 to the lower post 18. The first frame unit 12 may be attached to the footings 24 in a variety of ways, including by providing one or more threaded rods, bolts, rebar or the like anchored in cement and protruding from each footing 24. These threaded rods may be received by a corner plate or similar bracket at, for example, the inside corners of the first frame unit 12.

Although the front, left corner of the second frame unit 14 has been focused on, equivalent arrangements are provided at the other junctions between posts 18, primary girders 28 and secondary girders 30 and 32. With reference now to FIG. 8, another view of the front left corner of the second frame unit 14 is shown, although from a different angle. In particular, a box 72 is shown in ghost lines which links an opening 74 in the secondary girder 32 with an opening 76 in the transverse frame 46. This box 72, also seen in FIGs. 5 to 7, links the vertical and transverse channels 60 within the frame 46 with the space between the floor 38 and the ceiling 58 therebelow (both shown in FIG. 3b). Additional openings can be provided transversely through the primary girders 28, thereby linking the spaces within frame units 12, 14 or 16. It will be appreciated that heated or cooled air could be circulated throughout the structure in this manner. Discreet conduits, such as hoses, pipes, sleeves and the like, could also be passed through the channels 60 and the box 72.

With reference to the FIGs. 9a and 9b, each footing 24 preferably comprises a base 78 and a rim 80 extending upwards, concentrically therefrom. Each footing 24 is preferably hollow, providing a central void area 82 into which concrete can be poured and shaped and sized to support the first frame unit 12, and in particular the primary and secondary girders 18, 30 and 32. Preferably the footings 24 are formed from a moulded plastic, for example urethane. When two modular block units 20 are installed in a side by side arrangement, their adjacent primary girders 28 will share one or more footings 24.

A series of vertical slots 84 are provided in pairs around the circumference of both the base 80 and the rim 82. The slots 84 are advantageously able to receiving lateral edges of lower walls 50 such as that shown in FIG. 2, or other external panels which close and isolate the area beneath the first frame unit 12. Certain slots 84 may be provided at different angles in order to accomplish different tasks. For example, two opposed slots 84 may be sized and shaped to receive transverse lower walls, while the two other slots 84 may be sized and shaped to receive longitudinal lower walls.

With reference to FIG. 10a, three variations 20', 20" and 20'" of a modular block unit 20 are represented schematically. The three modular block units 20', 20" and 20'" have the same trapezoidal shape. As before, the short and long transverse sides will generally be designated as the "rear" side 86 and the "front" side 88, respectively, although this designation is purely for explanation purposes and should not be considered limiting.

The first modular block unit 20' is provided with rear and front sides 86 and 88 of equal height and therefore its upper side 90 is flat. The second modular block unit 20" is constructed to be higher in the front than in the rear and the upper side 90 therefore slopes downwards from the front side 88 to the rear side 86. Lastly, the third modular block unit 20'" is arranged in the opposite manner as the second unit 20", that is to say an upper surface 90 which slopes downwards from rear to front.

It will be appreciated that these three exemplary units 20', 20" and 20'" can be arranged in various combinations to form buildings. Four such buildings 100a, 100b, 100c and 100d are illustrated in FIG. 10b. These structures may be arcuate, as per the structures 100a, 100b and 100c, or may be substantially straight as per the structure 100d.

A completed two-storey building 100, constructed from six modular block units 20, is shown in FIG. 11. In addition to the front and rear walls discussed previously, additional longitudinal side walls 92 have been installed between the outer primary girders 28 (not shown) in order to enclose the space therewithin. Various outer panels and shielding components have also been added to protect the modular block units 20 from the elements and/or for aesthetic purposes.

With reference to FIGs. 12a and 12b, another embodiment of the present invention is shown. In this embodiment, the girders 28, 30 and 32 and the joists 34 are primarily made of steel, although the primary girders 28 are composed both of steel and wood. A series of brackets 94 are used to mount the secondary girders 30 and 32 to the posts 18.

It will be appreciated that the curved shapes enabled by the modular construction system 10 may be more desirable to a designer or consumer than a structure built from a conventional, rectangular system. It will further be appreciated that the system 10 enables more versatility in the design process and a greater range of design possibilities. It will also be appreciated that a curved structure 100 constructed from the system 10 may be designed with improved aerodynamic characteristics and performance in windy conditions due to its curved shape. It will further be appreciated that in contrast with a conventional rectangular structure, a curved structure 100 built from the modular construction system 10 may maximize the view available to the occupants therein, as well as maximize the amount of sun received through its windows. Moreover, a curved structure 100 will similarly favor the positioning of solar panels thereon since the structure is able to better face the sun. Again when compared to a conventional rectangular structure, it will also be appreciated that a curved structure 100 may enable an advantageous use of space by minimizing the space lost to square corners.

Of course, numerous modifications could be made to the embodiments above without departing from the scope of the present invention.

As being now better appreciated, the present invention is an improvement and presents several advantages over other related systems and/or methods known in the prior art.

Claims

1. A modular construction system for constructing a building comprising: a) a plurality of frame units, each frame unit having a trapezoidal shape and comprising: i) a pair of opposed unparallel primary girders of equal length; and ii) a pair of opposed parallel secondary girders of different lengths, interconnecting the primary girders; and b) a plurality of posts for mounting the frame units one above another so as to construct at least one modular block unit of the building.

2. The modular construction system of claim 1 , further comprising a plurality of footings for supporting said at least one modular block unit on ground surface.

3. The modular construction system of claim 2, wherein said at least one modular block unit has four upper corners and four lower corners and the footings are positionable respectively under at least each one of the lower corners of the modular block unit.

4. The modular construction system of claim 1 , wherein a number of the plurality of frame units are floor frame units provided with a plurality of floor panels mounted thereon.

5. The modular construction system of claim 1 , wherein a number of the plurality of frame units are roof frame units provided with roof panels mounted thereon.

6. The modular construction system of claim 5, wherein the plurality of posts comprises short posts and long posts so as to construct at least one of said block unit with a sloped roof.

7. The modular construction system of claim 1 , further comprising a transverse frame for extending vertically between two levels of the modular block unit.

8. The modular construction system of claim 1 , further comprising a longitudinal frame for extending vertically between two levels of the modular block unit.

9. The modular construction system of claim 8, wherein the transverse frame comprises a plurality of panels.

10. The modular construction system of claim 9, wherein the transverse frame unit comprises a channel for extending parallel to the secondary girders and a channel for extending parallel to the posts.

11. The modular construction system of claim 10, further comprising an isolated space bounded by a one of the plurality of frame units, the channels being connected to the isolated space.

12. The modular construction system of claim 1 , wherein the posts are connectable to adjacent primary girders by vertical rods.

13. The modular construction system of claim 1 , wherein the posts are tapered.