WO2013079971A2

WO2013079971A2 - Improvements relating to construction

Info

Publication number: WO2013079971A2
Application number: PCT/GB2012/052978
Authority: WO
Inventors: Terry Came
Original assignee: Terry Came
Priority date: 2011-11-30
Filing date: 2012-11-30
Publication date: 2013-06-06
Also published as: GB2497099A; GB201120622D0; WO2013079971A3

Abstract

Construction modules formed from cruciform construction elements (1) having a main body (2); first and second arms (3, 4) extending from the main body, the first and second arms being in alignment with one another along a first direction; and third and fourth arms (5, 6) extending from the main body, the third and fourth arms defining upper and lower surfaces and being in alignment with one another along a second direction that is substantially at right angles to the first direction.

Description

Improvements relating to construction

Field of the Invention

The current invention relates to construction modules and their parts, as well as structures formed from construction modules. In particular but not exclusively the invention relates to construction modules for producing buildings, for example wooden buildings that have good thermal integrity.

Background of the Invention

Historically, buildings have been built using solid material to form walls of the building, such as stone, concrete blocks or bricks. Older buildings were constructed of single walls and the thermal insulation of such buildings was very poor. In more recent times, buildings have been constructed from double walls which have a cavity between them. Insulation material can be pumped into the cavity to increase the thermal insulation of such buildings, but there are problems in that often cavity walls have tie bars in them that form a bridge between the two walls and which help to prevent bowing of the walls. Because there is a metal bridge between the two walls, there can be thermal leakage from the building due to the conductivity of the metal and composite tie bars.

More recently buildings have been constructed by using an internal frame to which walls are attached by using a cladding method where sheets of material such as plasterboard are attached to the frame. Alternatively the frame can form the main supporting structure of the building and walls, typically made of concrete blocks, provide an infill for the frame. Usually the framework for a building is made from metal girders, typically steel. The walls of the building are made from a separate material from the frame and, as there are separate elements which have to be joined or abutted against one another, there are typically points in the building structure where there is thermal leakage. This leads to a less energy efficient building and increased costs to heat the building. For new builds, having reduced thermal efficiency can mean that a building may not be able to meet the energy efficiency standards that regulatory authorities require new buildings to meet. Furthermore, known buildings do not allow for the provision of service ducts which are integral with the building and which allow for easy access to those service supplies, such as electricity wires or water supplies, once the building is constructed.

The present invention seeks to overcome the problems of the prior art by providing thermally efficient construction modules that allow for convenient construction of buildings whilst retaining ease of access to services. Furthermore the invention allows for a building that is flexible in its ability to adapt to the occupants' needs and desires and changing technology.

Summary of the Invention

According to a first aspect of the invention, there is provided a construction module comprising: a plurality of cruciform construction elements arranged in a linear array, each of said elements having: a main body; first and second arms extending from the main body, the first and second arms being in alignment with one another along a first direction; and third and fourth arms extending from the main body, the third and fourth arms defining upper and lower surfaces and being in alignment with one another along a second direction that is substantially at right angles to the first direction; and at least one building element supported by the construction elements and linking the construction elements in the linear array.

This construction module provides for a linked array of construction elements that is useful in construction, for example to support walls. Due to its modular nature, the construction module may be conveniently and advantageously built to a variety of forms and sizes and combined with other building materials as appropriate.

Each construction element comprises a central axis from which the first, second, third and fourth arms extend radially. In an embodiment of the invention, the at least one building element is elongate and extends substantially parallel to the central axis of at least one construction element (and preferably all construction elements that it links).

Advantageously, two of the building elements may be supported by the upper surfaces of the third and fourth arms of at least first and second construction elements, and a further two building elements attached to the lower surfaces of the third and fourth arms of at least the first and second construction elements, the arms of the construction elements extending radially from a concentric axis of the construction elements and the building elements extending substantially parallel to said axis. Such a "boxed" construction module provides for excellent strength, as well as good insulation properties and spaces for the incorporation of services for buildings.

It is thus envisaged that the construction module may be provided with a plurality of construction elements placed in a linear arrangement with the first and second arms of each cruciform element being arranged substantially vertically and the third and fourths arms being perpendicular to the first and second arms, the third and fourth arms having respective upper and lower surfaces that provide the facility whereby up to four building elements can be attached to the construction element thereby providing a box beam or box truss having a composite structure.

Preferably the building element is a cross beam. In an embodiment, each building element is a crossbeam positioned to bridge a space between construction elements, said crossbeam(s) being substantially at right angles to a major plane of the construction elements. In an embodiment of the invention, the construction elements are arranged at a distance of at least 400 mm from one another in a linear direction.

In an embodiment of the invention, the arms of each construction element define four recesses that each receive and locate an associated building element in the form of a crossbeam that extends substantially at right angles to the arms and links each construction element to an adjacent construction element.

In an embodiment of the invention, each construction element comprises a panel that has a cruciform plane, with the third and fourth arms having a greater width in the cruciform plane than the first and second arms. The panel may be unitary or a composite panel. In an embodiment, the panel comprises one or more mortised arms. One or more of the arms may have a lower thermal conductivity than the other arms. Preferably third and fourth arms may be of substantially equal length. In one embodiment, the first arm is longer than the second arm. Embodiments of the invention provide for spacing defined by the construction elements and building element(s), which spacing confers advantageous insulation properties but also facilitates the incorporation of services into structures incorporating the construction module.

To provide for particularly advantageous spacing, the first arms of at least two construction elements may comprise at least a section that stands proud of the building element(s), said first arms defining a support plane clear of and spaced from the building element(s). For example, as aforesaid, it is envisaged that the first arm may be longer than the second arm. In a preferred arrangement when in use, the first arm is positioned such that said first arm is uppermost of the second arm. The first arms may support, in the support plane, one or more panels forming a layer (e.g. a floor) that is spaced from the construction module, hence providing additional insulation and room for services.

In a preferred arrangement one or more of the arms may be made of a material with thermal qualities. In other words, one or more of the construction elements may comprise a material with a relatively low thermal conductivity, i.e. a material with a thermal conductivity of less than 0.4 W/(m.K), preferably less than 0.2 W/(m.K). It is envisaged that the construction elements and/or the building elements are made of wood or a wood composite. However is envisaged that other material may be used as they are developed in the construction industry.

For additional strength and separation, the construction module may further include facing panels attached to end surfaces of the third and fourth arms of the construction elements. The facing panels may be of any suitable material, e.g. wood.

In an embodiment of the invention, at least one construction element is integral with or attached to a column member. Advantageously, the column member may extend substantially at right angles to the building elements, along the first direction. The column member may form part of a support column comprising a plurality of members. Such a support column may, for example, comprise first and second parallel members defining one or more of said construction elements, with a load-bearing member interspersed between and attached to the first and second members. Where the construction module incorporates such a load-bearing member, it may comprise a plurality of construction elements on opposed sides of the load-bearing member. Each construction element is linked to at least one adjacent construction element by a building element.

The elements of the construction module may preferably be linked or attached to each other by an adhesive. Optionally, other fixing means such as screws or nails may be employed, though avoiding such other fixing means has the advantage of improved thermal insulation.

Advantageously, the construction module may comprise a plurality of beams constituting building elements, the beams being linked to each other by the construction elements such that at least first and second ones of the beams are obtusely angled with respect to each other. Such a construction module is of particular use in providing a kinked composite support for roofs.

The construction module may be used as a load-bearing frame for a structure. For example, the construction module may be used as a support frame for a wall of a building. The term "wall" as used herein embraces both external and internal vertical walls, as well as roofs, floors and ceilings.

From a second aspect, the invention provides a wall frame comprising one or more construction modules as described anywhere herein. From a third aspect, the invention provides a composite wall comprising inner and outer walls supported by a construction module as described anywhere herein.

Composite walls formed with the help of a construction module according to the invention have advantageous thermal insulation properties, can be built in a modular fashion, and provide spaces for services such as plumbing and electricity. Such walls may additionally offer the advantage of facilitating the incorporation of windows with the help of a customised glazing joint.

Advantageously, the composite wall according to the third aspect of the invention may further comprise a glazing joint wherein at least one edge of a glazing unit is positioned between the outer and the inner wall and is sandwiched therebetween without the need for a separate frame. The glazing unit may be sandwiched between the outer wall and a removable section of the inner wall. In an embodiment of the invention, the removable section of the inner wall comprises a formation for cooperating with a remaining section of the inner wall such that the removable section of the inner wall is held in place against the glazing unit in an interference fit, thereby sandwiching the glazing unit between the outer and the inner walls. The removable section may be positioned in proximity to where the at least one edge of the glazing unit abuts the inner wall panel and said removable section may be removable so that an inner face of the glazing unit can be revealed allowing the glazing unit to be removed from the wall. This allows for replacement of glass without the need for damaging the wall of the building, which conventional frame systems do and it is also a much easier system to use as the wall itself supports the glass.

It will be appreciated that the glazing joint can also be used independently of the construction module, in any composite wall having inner and outer walls. As such it represents a fourth aspect of the invention by itself, irrespective of the formation of the composite wall.

Embodiments of the invention are of particular benefit in forming floors or ceilings. In a preferred arrangement a composite wall or construction module forms a separation between an upper and lower floor of a building.

From a fifth aspect, the invention provides a composite wall, which may advantageously be a floor, comprising: a construction module in which the first arms of at least two construction elements comprise at least a section that stands proud of the building elements, said first arms defining a support plane clear of and spaced from the building elements; and one or more panels supported by the first arms of said at least two construction elements, the panels being supported in the support plane and defining a wall layer that is spaced from the building elements of the construction module.

From a sixth aspect the invention provides a kit for forming any of the modules or other structures defined herein. Such a kit may comprise a plurality of cruciform construction elements as described anywhere herein; and one or more building elements for linking the construction elements in a linear array. According to a seventh aspect, the invention also embraces a construction element for forming any of the modules or other structures defined herein. The construction element may be as described anywhere herein.

In an eighth aspect of the invention there is provided a building having one or more construction modules according to the invention. The construction modules, typically form supports for the roof and ceiling between floors in a building. The construction modules are particularly suited to forming a roof structure as separate modules can be joined to one another forming a continuous structure, and in particular one having a change in angle of the profile.

The invention also embraces suitable methods of forming the construction modules by linking construction elements and building elements as described herein. In an embodiment, the elements may be linked by gluing.

The invention has particular advantages in that it allows for a cost effective building system, which minimizes the materials used, and provides a good thermal rating for the building whilst allowing for adaptability of the building structure.

Brief Description of the Figures

An embodiment of the invention will be described with reference to and as illustrated in the accompanying figures by way of example only, in which:

Figure 1 shows: a number of different known types of composite beam structures that can be used to form frames, trusses, beams and purlins in a building;

Figure 2 shows: a perspective view of a construction module incorporating a number of construction elements according to an embodiment of the invention in situ;

Figure 3 shows: a side view of the arrangement of Figure 2, with cladding in position; Figure 4 shows: a view from above of the arrangement of Figure 2, illustrating the spaced relationship of the construction elements with there being apertures between them for receiving services;

Figure 5 shows: a cross section through a 'Composite Box Beam' and composite wall;

Figure 6 shows: a 'Composite Box Beam Truss', roof arrangement with a number of construction modules joined to one another to provide a support for the roof of a building; and

Figure 7 shows: a glazing structure used with a wall constructed using a construction module according to the invention.

Detailed Description of Embodiments of the Invention

Figure 1 shows a series of known construction elements that are used in buildings to date. Typically building elements are provided as either vertical or horizontal elements that provide the framework for the building and cladding is nailed or screwed to the elements. There has to be a specific fixing of the cladding to the construction element rather than the construction element having inherent features that allow it to support a building element. Furthermore, the construction elements provide a solid vertical wall and there is generally no spacing to allow for the introduction of services such as drainage, water, media or electrical supplies and these have to be included in the building outside of the wall. This means that service ducts are visible or alternatively they have to be embedded in the wall itself once the wall is built. They are not incorporated in cavities formed as part of the wall structure so there are problems in retaining ease of access to these service ducts.

Figure 2 shows a perspective view of a construction module incorporating a series of construction elements according to an embodiment of the invention which are in situ. These construction elements are generally shown as 1 in the figure. Each construction element has four arms, with first and second arms 3 and 4 being in a linear arrangement with the first arm 3 being positioned above the second arm 4. There are also second and third arms 5, 6 that are again in alignment and are at substantially right angles to the first and second arms 3, 4. The first arm 3 is longer than the second arm 4 and the construction elements are generally cruciform. There is a main body or core 2 for the cruciform structure where all four arms 3, 4, 5, 6 meet that provides stability to the whole structure. In this arrangement the building is a timber building and so the construction elements are made of timber, but other materials may be used. Timber is a particularly useful material to use for buildings that include the construction elements of the invention because timber is readily available and has thermal insulation qualities. Timber is also sustainable, which is particularly important for eco buildings.

The first arm 3 ends in an end surface 7. Similarly there is an end surface on the lower second arm 4. The end surface 7 of the first arm abuts a floor or a roof member positioned above the construction element 1 and provides a strengthening element, while the end surface of the second lower arm 4 is visible to a room beneath and may be covered with a decorative finish. The third and fourth arms 5, 6 have an upper cross surface 8 which forms a shoulder onto which a cross beam 10 can be placed. This cross beam runs parallel to the floor and ceiling and provides strength, combining with the construction elements to form the construction module, in this case a composite box beam truss. Composite walls (18, 18a, 19, 19b figures 4 & 5, and 31, 31b of figure7) provide weather proofing, thermal insulation and racking stability to the composite box beam truss. The third and fourth arms 5, 6 also have an underside to which other cross beams can be attached so forming a secure structure to which walls can be attached. The third and fourth arms 5, 6 have respective end surfaces 9 to which a facing panel 13 can be attached to cover the cross beams 10 and the cruciform elements 1. The facing panel 13, which is typically birch ply may be secured to the end surfaces by gluing, which avoids the need for separate fixings, which are typically metal, which not only are unsightly but which means that heat can be lost through conduction via the metal. Indeed, all of the components described hereinabove may suitably be affixed to each other using suitable adhesive known in the art.

Each cruciform construction element 1 can have four cross beams 10 (timber booms) placed edge-on onto the cruciform element, two on the upper surface of the third and fourth arms 5, 6 of the cross and two below the third and fourth arms 5, 6 of the cruciform element. The cruciform elements 1 together with the four cross beam elements 10 (commonly referred to in the construction industry as a boom) form what we call a construction module or "composite" box beam. It is preferable to use SC24 structural grade timber or above for its structural properties, and these beams can be glued in accordance with TRADA (Timber Research and Development Association) best practice and/or screwed to the construction elements or fixed using other types of mechanical fixings that are known in the construction industry.

The construction elements 1 are typically made from a mortised piece of wood and an upper mortise (which we refer to as an arm) is extended above the beam (to the depth of joist/roof members) to allow for joining to floor and roof members. It is preferable for the upper first arm 3 to be 75mm or greater in length, to allow for a service void in the beam - and allow 75mm of timber to remain in-between two rebates or recesses that receive the booms. The cruciform that is formed, and which is mortised, takes the load path through the centre of the construction element to prevent the cross beams 10 from being damaged by compression actions. The construction elements are placed preferably at 400mm from centre to centre from one another in a linear direction. Thermal insulation is placed/glued in-between upper and lower beams 10, and should equal the thickness of the beams.

The cross beams 10 are supported by columns 11. The columns 11 are load bearing and extend along the same direction as the first and second arms of the construction elements. The columns are preferably three pieces of SC24 grade timber, 145 x 195mm for intermediate columns and at the comers/ends of a building, with the direction of growth rings set in opposing orientation to each other in line with accepted best practice to reduce the risk of the column twisting. The pieces (or members) of the column are glued together. The middle member acts as the main load/actions support, with some transference of actions to the outer members. The outer two members have housing joints cut 12, 12b (rebated) to receive the beams 10. Thus the outer two members effectively comprise an integral construction element 1. The cross beams 10 are to be structurally glued (in accordance with TRADA best practice) or secured by other mechanical fixings to the column 11. The elements of the 'Composite Box Beam' together with the columns form a 'Composite Box Beam Truss'. Typically columns that are internal in a building (intermediate columns) are made of three sections and columns that end on the outside of a building are made from two sections. The centre section of the column (for intermediate columns) and the section on the outside end of corner columns can be extended into the building as illustrated by 1 lb in Figure 2, which shows a cut-out 11c only for illustrative purposes). There can also be attached a portal beam (not shown) that extends perpendicularly to the composite box beam truss. A portal beam can be attached to the extended column in line with current building best practices to provide a portal or moment frame. On an external perpendicular wall, the outer member of the column has housing joints cut (rebated) to receive the portal beam 14 (see Figure 6) that is running perpendicular to the 'Box Beam Truss'. This system is preferable to the conventional way of securing beams to a supporting upright using 'L' shaped steel (angle bracket) facing out from the column, as this would seriously compromise thermal integrity, and most likely cause thermal bridging and subsequent condensation/damp problems. Optionally there may be a timber portal that is perpendicular to the box beams and this avoids the need for walls to provide racking stability for the structure. The avoidance of the need for walls produces a building with more open spaces. Joists 30 extend between the composite box truss structures on opposite walls to provide strength to the arrangement.

A webbing or facing panel 13 of preferably birch ply (not birch faced) is glued to both sides of the beam 10, and/or can be nailed or attached by another mechanical fixing to the beam 10 and column 11. Birch ply is used for its higher resistance to shear actions, which is provided if nailed, preferably nailed with 50 mm galvanised ring shanks at 50 mm centres for 400 mm past high stressed areas such as junctions with columns and changes in the angle of beams. However a method of attaching parts can be the use of a structural glue joint according to TRAD A best practice.

The columns 11 can be secured to a building foundation via appropriately sized bolts protruding from the foundations and connected to a metal shoe/bracket (not shown). In earth quake prone areas the metal shoe can be substituted with a shock absorbing shoe already on the market and used with steel frames. The bolts and shoe method allows for a very easy and accurate levelling of the building frame. This gives a big advantage over other panel type buildings, as in practice slight imperfections in levels of the foundations are exaggerated in poorly fitting panels as the building height increases. As an alternative the columns 11 can be set in concrete. Figure 3 shows a side view of a construction module with facing ply 13. The first, upper arm 3 of the cruciform element can be seen and there is spacing 15 between each of the elements 1. This spacing forms a cavity through which services such as pipes for a water supply or sewage may be run. At the upper end of the first arms 3, there is provided a flooring element 16 such as plasterboard or fire board for containment of fires between floors and to provide mass for sound retention/insulation between floors and attached buildings. On top of this there may be a sound insulating layer 16a, followed by the actual flooring layer itself, which may be boarding or a laminate 16b. A joist 30, adjacent the first arms 3 provides further support for the flooring.

As can be seen in Figure 4, which shows a view from above, there are not only spaces that run in the same linear direction as portal beams (shown as 15 in Figure 3) but there are also spaces that extend vertically between the first arms 3. Such spaces allow for the running of services between floors of a building and from one side of a room to another in the space that is provided between the ends of the arms 3, 4, 5, 6. The column 11, with central section 11a provides a supporting structure and there is a facing layer 18a attached to a main racking board, which is thus attached to the cross beam 10 of the construction module. There is also an insulation layer 18 followed by an exterior layer 19, which may be wooden shingles, or any other finishing material. The structural timber skeleton provides support for the main loads/actions associated with buildings. With a composite external skin laminated in situ, the external skin and internal composite stress diaphragms provide for the main racking actions of the building. Suitably, panels between columns and beams can be factory made, complete with internal decorative finishes as part of a kit, with external finish/cladding fitted/applied on installation. It is envisaged that towards the centre of each bay (the area in between two 'Box Beam Trusses') running parallel to the 'Box Beam Trusses' is a section of dropped ceiling approximately 600mm wide with easily removable panels, and deep enough to allow for appropriately sized fall for waste pipes, ventilation pipes and other services.

Figure 5 shows an end view of a section cut through the an external wall and the 'Composite Box Beam'. The core 2 of the construction element 1 is shown with four arms. As the third arm 5 is to be located at an area of the building where there may be particular heat leakage, it may be coated with or made from a material which has particularly good insulating properties but which retains its strength to support beams 10. The outer skin of the wall may be shingles or rendering 19, which may be one layer or more preferably is multilayered. Inwardly of the outer skin there is a vapour/moisture layer 19a and then an orientated strand board layer 19b. There is then a rigid insulation layer 18, which may be foam or a natural material such as compressed paper of animal hair fibres, e.g. sheep's wool all bonded together. The other side of the insulation layer has a repeat of the orientated strand board. There are beams 10 and the cruciform construction element 1 with the central part of the element being shown as 2. Joists 30 (or portal beams) run at right angles to the plane of the cruciform element 1 and form the support for a ceiling of a floor below.

A building structure can be seen in Figure 6. The individual rooms a, b, c, d, e, f and g are shown and different floors of the building are separated by construction modules including a series of construction elements which form the structure for the support of floors/ceilings 20, 21. The structure is supported using columns 11, which for intermediate columns have three uprights, while for the end columns there are two uprights. The three part columns in particular allow for the support of portal beams 14. At the top of the building the construction modules form a hipped roof structure formed of a flat roof section 22 from which extends a sloped roof section 23. These roof sections connect with vertical wall of the building. The construction modules can go from horizontal to a pitch roof angle without the need for column or load bearing wall support as the construction modules form an integral load supporting arrangement. The construction provides for a complete thermal insulation layer 22a that surrounds the building. The modules are mechanically fixed with glue to columns/booms and studs (cruciform elements) at spaced locations, typically 400mm centres. Again the gluing complies with TRADA structural gluing requirements. The construction which uses the construction modules as support for the roofing rather than having conventional A frame beams allows for a greater use of roof space as a usable inhabitable area for the buildings use - especially in building height restricted areas, as there is less requirement for internal structures to support the roof structure.

All floor and roof timbers run perpendicular to 'Box Beam Truss' (except roof timbers that are on a hipped roof), and are fixed to protruding studs (not shown), preferably by gluing or other mechanical fixing. This also allows for easy fitting and updating of services within the building. The sizes of the beams/columns and its component parts will depend on what actions/loads they will need to take in each particular building. When building a wooden structure the construction system uses less timber volume than conventional timber frame buildings and provides a very high level of thermal integrity over and above other methods of construction. Furthermore the building system will have a higher thermal integrity than a Structural Insulated Panel (SIP's) system. The building system has an integral strengthening system using the cruciform construction elements described to allow for more storeys to be included in a building as they are of greater strength than known systems and have higher thermal integrity. Furthermore as the verticals are an integral part of the building, they can be incorporated in the foundations of the building easily. This may be via bolting the uprights to plates in the ground which allow for a degree of movement in geographically unstable areas such as earth quake prone areas. Alternatively rather than using plates in the ground, the uprights may be fixed to for example vertical pins that have areas of resilience that allow for movement in the building. The building securing system is generally shown as 24 in the figure. As the modular construction system forms the structural framework of the building, it is particularly strong as it in effect provides a monocoque structure which itself is load supporting.

Finally, the building system described, where the construction modules form a strong supporting structure for a building, also allow for a direct frameless glazing system as shown in Figure 7. This figure shows a view from above of a glazing system incorporated in a building structure of the invention. The glazing is shown as triple glazing 25 formed of three pieces of glass separated by layers of air or other gases such as Argon, which provides good insulation. As well as triple glazing, double or multiple glazing systems could be used. The ends of the panes of glass have thermal insulation layers 26, which provide insulation between the glazing and the building itself. The gap between the face of a glazing panel and a wall 27a that forms the external wall of a building is sealed with a sealant 33 such as silicon beading which again maintains the thermal integrity of the structure and keeps the glazing system water tight. There may also be an aluminium plate to provide further protection at this joint. At the ends of the glazing there may also be a foam layer 34 which provides further thermal integrity. An inner wall section 27b abuts against an inner face of the glazing structure. On the inner side of the glazing there is another sealing entity, which is non-bonded. Next to the non-bonded sealing layer there is an internal insulation part 35, which not only protects the internal seal, but also further helps with thermal integrity of the system. The inner wall section 27b extends to a block 28 which has a channel 36. The channel may be lined with a material that provides a protective surface such as a plastic or a metal such as aluminium. The channel can receive primary sheathing/racking 31 that is supported by the channel 36 in the thickened part 28 of the wall so providing a strengthening support. The inner wall section 27b, including the block 28, and the insulation part 35 are bonded together to form a glazing bead. Typically for ease of access the glazing bead is push fitted into place. There is also a surface layer 30 such as plaster board which provides a wall and this is backed by insulation layer 32 to keep the whole wall thermally insulated.

If the glazing is to be removed, the block 28, the insulation part 35 and the inner wall 27b can be detached. This allows for the glazing to be brought away from external wall 27a and detached from its position so it can removed and replaced if required. The way that the construction elements allow for the build-up of construction modules means that the glazing can be incorporated in the building structure itself by being clamped between two walls rather than having to use window frames. Again the modular system described forms an integral monocoque structure with high strength and thermal integrity because of the reduction of the need for separate building elements which have to be secured together thereby creating lines of weakness with regard to strength and for retaining heat within the construction.

This glazing system has particular benefits in that under current building regulations in the UK, windows and doors are restricted to a certain percentage of a building's floor area. The windows and doors are measured over the opening into which they are to be inserted, including the frames. The glazing system of the current invention not only exceeds current heat transfer coefficient values (U values) by three times, but it also increases the amount of light going into a building, so making the building much more pleasant for occupants.

Furthermore, embodiments of the present invention allow for a much slimmer wall profile (being 255mm - including a 32 mm service void) compared with a conventional wall which is typically 327 mm, and depending on the accuracy of construction, with no service void. This means that the wall is substantially slimmer (typically 104mm) and at the same time has far superior thermal properties and this is due in part to wall not taking direct loads. The present invention therefore also allows for constructing buildings having more space for the building footprint as walls are thinner but at the same time providing a very thermally efficient structure, which minimises environmental impact as less heating will be needed to heat such structures due to the minimization of heat leak.

It is to be understood that the above embodiments have been provided only by way of exemplification of this invention, such as those detailed below, and that further modifications and improvements thereto, as would be apparent to persons skilled in the relevant art, are deemed to fall within the broad scope and ambit of the present invention described. Furthermore where individual embodiments are discussed, the invention is intended to cover combinations of those embodiments as well.

Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of the words do not exclude other components, integers or steps. Moreover the singular encompasses the plural unless the context otherwise requires: in particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Preferred features of each aspect of the invention may be as described in connection with any of the other aspects unless incompatible therewith. Generally speaking the invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims and drawings). Thus features, integers or characteristics described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. Moreover unless stated otherwise, any feature disclosed herein may be replaced by an alternative feature serving the same or a similar purpose.

Claims

1. A construction module comprising:

a plurality of cruciform construction elements (1) arranged in a linear array, each of said elements having: a main body (2); first and second arms (3, 4) extending from the main body, the first and second arms being in alignment with one another along a first direction; and third and fourth arms (5, 6) extending from the main body, the third and fourth arms defining upper and lower surfaces and being in alignment with one another along a second direction that is substantially at right angles to the first direction; and at least one building element (10) supported by the construction elements and linking construction elements in the linear array.

2. A construction module according to claim 1 wherein two of the building elements (10) are supported by the upper surfaces of the third and fourth arms (5, 6) of at least first and second construction elements (1), and a further two building elements (10) are attached to the lower surfaces of the third and fourth arms of at least the first and second construction elements, the arms of the construction elements extending radially from a concentric axis of the construction elements and the building elements extending substantially parallel to said axis.

3. A construction module according to any preceding claim wherein the building element (10) is a crossbeam positioned to bridge a space (15) between construction elements, said crossbeam being substantially at right angles to a major plane of the construction elements (1).

4. A construction module according to any preceding claim, wherein the construction elements (1) are arranged at a distance of at least 400mm from one another.

5. A construction module according to any preceding claim, wherein the arms of each construction element (1) define four recesses that each receive and locate an associated building element (10) in the form of a crossbeam that extends substantially at right angles to the arms and links each construction element to an adjacent construction element.

6. A construction module according to any preceding claim, wherein each construction element (1) comprises a panel that has a cruciform plane, with the third and fourth arms (5, 6) having a greater width in the cruciform plane than the first and second arms (3, 4).

7. A construction module according to any preceding claim, wherein the first arms (3) of at least two construction elements (1) comprise at least a section that stands proud of the building elements (10), said first arms defining a support plane clear of and spaced from the building elements.

8. A construction module according to any preceding claim, wherein one or more of the construction elements (1) comprises a material with a thermal conductivity of less than 0.2 W/(m.K).

9. A construction module according to any preceding claim, wherein the construction elements (1) comprise wood or a wood composite.

10. A construction module according to any preceding claim further including facing panels (13) attached to end surfaces of the third and fourth arms (5,6) of the construction elements.

11. A construction module according to any preceding claim wherein at least one construction element (1) is integral with or attached to a column member (1 1).

12. A construction module according to claim 11, wherein the column member (1 1) extends substantially at right angles to the building elements (10), along the first direction.

13. A construction module according to claim 11 or claim 12 wherein the column member (11) forms part of a support column comprising a plurality of members (11, 11a).

14. A construction module according to claim 13 wherein the support column comprises first and second parallel column members (11) defining one or more of said construction elements (1), with a load-bearing member (1 la) interspersed between and attached to the first and second members.

15. A construction module according to claim 14 comprising a plurality of construction elements (1) on opposed sides of the load-bearing member (11a).

16. A construction module according to any preceding claim comprising a plurality of beams (10) constituting building elements, the beams being linked to each other by the construction elements (1) such that at least first and second ones of the beams are obtusely angled with respect to each other.

17. A wall frame comprising one or more construction modules according to any preceding claim.

18. A composite wall comprising inner and outer walls supported by a construction module according to any one of claims 1 to 16.

19. A wall according to claim 18 further comprising a glazing joint wherein at least one edge of a glazing unit (25) is positioned between the outer and the inner wall (27a, 27b) and is sandwiched therebetween without the need for a separate frame.

20. A wall according to claim 19 wherein the glazing unit is sandwiched between the outer wall (27a) and a removable section of the inner wall (27b).

21. A wall according to claim 20 wherein the removable section of the inner wall (27b) comprises a formation for cooperating with a remaining section (31) of the inner wall such that the removable section (27a) of the inner wall is held in place against the glazing unit (25) in an interference fit, thereby sandwiching the glazing unit between the outer and the inner walls.

22. A wall according to claim 20 or claim 21, wherein the removable section (27b) is positioned in proximity to where the at least one edge of the glazing unit (25) abuts the inner wall and said removable section is removable so that an inner face of the glazing unit can be revealed allowing the glazing unit to be removed from the wall.

23. A composite wall comprising a construction module according to claim 7 and one or more panels (16) supported by the first arms (3) of said at least two construction elements (1), the panels being supported in the support plane and defining a wall layer that is spaced from the building elements (10) of the construction module.

24. A kit for forming a construction module according to any one of claims 1 to 16, the kit comprising a plurality of cruciform construction elements (1) having: a main body (2); first and second arms extending from the main body (3, 4), the first and second arms being in alignment with one another along a first direction; and third and fourth arms (5,6) extending from the main body, the third and fourth arms defining upper and lower surfaces and being in alignment with one another along a second direction that is substantially at right angles to the first direction; and one or more building elements (10) for linking the construction elements in a linear array.

25. A cruciform construction element (1) for forming a construction module according to any one of claims 1 to 16, the construction element comprising a main body (2); first and second arms (3, 4) extending from the main body (2), the first and second arms being in alignment with one another along a first direction; and third and fourth arms (5,6) extending from the main body, the third and fourth arms defining upper and lower surfaces and being in alignment with one another along a second direction that is substantially at right angles to the first direction.

26. A construction element according to claim 25 comprising a panel that has a cruciform plane, with the third and fourth arms (5, 6) having a greater width in the cruciform plane than the first and second arms (3, 4), the first arm being longer than the second arm and the third and fourth arms being of substantially equal length.