U.S. patent application number 12/584703 was filed with the patent office on 2010-03-11 for building-insert module and associated methodology.
This patent application is currently assigned to ConXtech, Inc.. Invention is credited to Robert J. Simmons.
Application Number | 20100058675 12/584703 |
Document ID | / |
Family ID | 41798014 |
Filed Date | 2010-03-11 |
United States Patent
Application |
20100058675 |
Kind Code |
A1 |
Simmons; Robert J. |
March 11, 2010 |
Building-insert module and associated methodology
Abstract
A prefabricated, building-insert module adapted for insertion to
create in-place room infrastructure in an open, plural-story, main,
column-and-beam building frame which is defined by columns and
beams, the module including a prepared floor sub-module having an
upper surface, and an at least partially completed,
three-dimensional room sub-module anchored to and rising upwardly
from the upper surface of the floor sub-module. The floor
sub-module acts variously as a fabrication, transportation and
installation-lifting pallet for the entire module, and the room
sub-module is placed in a continuous state of vertical compression
so as never, during transportation, lifting, and ultimate, in-place
installation, to go into a state of vertical tension.
Inventors: |
Simmons; Robert J.;
(Hayward, CA) |
Correspondence
Address: |
ROBERT D. VARITZ, P.C.
4915 SE 33RD PLACE
PORTLAND
OR
97202
US
|
Assignee: |
ConXtech, Inc.
|
Family ID: |
41798014 |
Appl. No.: |
12/584703 |
Filed: |
September 9, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61191694 |
Sep 10, 2008 |
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Current U.S.
Class: |
52/79.1 ;
52/236.3; 52/745.13 |
Current CPC
Class: |
E04B 1/34807 20130101;
E04G 21/142 20130101; E04B 1/34869 20130101 |
Class at
Publication: |
52/79.1 ;
52/745.13; 52/236.3 |
International
Class: |
E04H 1/00 20060101
E04H001/00; E04B 1/19 20060101 E04B001/19 |
Claims
1. A system featuring a prefabricated, building-insert module
adapted for insertion to create in-place room infrastructure in an
open, plural-story, main, column-and-beam building frame which is
defined by columns and principal beams, said module comprising a
floor sub-module having an upper surface, and an at least partially
completed, three-dimensional room sub-module anchored to and rising
upwardly from said upper surface of said floor sub-module.
2. The system of claim 1, wherein said room sub-module has a
defined footprint, and said floor sub-module has a perimetral
configuration and outline defining a floor sub-module footprint
which is permissively independent of said room sub-module's said
defined footprint.
3. The system of claim 1, wherein the building frame has plural
story levels each characterized by a grid of relatively angularly
disposed beams defining a plurality of distributed, next-adjacent
story panes having perimetral outlines each defining a beam-grid
footprint, and said floor sub-module's said defined footprint is
permissively independent of said beam-grid footprint.
4. The system of claim 1, wherein the building frame is a
plural-story building frame, and said module includes pick
structure operatively connected to said floor sub-module and said
room sub-module, constructed to enable machine lifting of the
module to an elevation in the frame which is above ground level
using the module's floor sub-module as a lifting pallet.
5. The system of claim 4, wherein said pick structure includes
elongate tensioned structure anchored to said floor sub-module, and
placing said room sub-module in a condition of vertical
compression.
6. The system of claim 4, wherein the building frame is made of
steel, and said floor sub-module includes lateral edges formed with
steel lateral edge structure which is attachable, as by welding, to
the steel in said frame, and a concrete floor body contained within
said edge structure.
7. The system of claim 1, wherein the building frame is made of
steel, and said floor sub-module includes lateral edges formed with
steel lateral edge structure which is attachable, as by welding, to
the steel in said frame, and a concrete floor body contained within
said edge structure.
8. The system of claim 1, wherein said floor sub-module is
constructed to act, for said module of which it is a part, at least
as one of (a) a room sub-module fabrication pallet, (b) a module
transport pallet, (c) a module lifting pallet, and (d) a
fire-resisting structure for and adjacent the underside of said
room sub-module.
9. A building-insert module methodology associated with an open
building frame which is defined by columns and beams, said
methodology comprising creating a prefabricated module structure
including (a) a floor sub-module having an upper surface, and (b)
an at least partially completed, three-dimensional room sub-module
anchored to and rising upwardly from the upper surface of the floor
sub-module, with the created floor sub-module performing as a
fabrication pallet for the creating of the room sub-module,
transporting the module to an insertion staging site located
adjacent such a building frame using the module's floor sub-module
as a transport pallet, and from the mentioned staging site, lifting
the thus transported module and inserting it into a selected
location within the frame using the module's floor sub-module as a
lifting pallet.
10. The methodology of claim 9, which further comprises, following
creation of the mentioned room sub-module, placing that sub-module
in a condition of vertical compression.
11. The methodology of claim 10, wherein said placing in
compression involves utilizing tensioned pick structure which forms
part of the created module, and said placing in compression is
implemented to create a state of vertical compression in the room
sub-module which will not allow the room sub-module to enter a
state of vertical tension during said lifting.
12. A plural-story building structure comprising a column-and-beam
building frame defining plural floor levels, on at least one of
said levels, an installed, and building-frame-attached,
building-insertion module having a floor sub-module and an
overhead-supported room sub-module, and module-specific
force-applying structure, independent of said building frame and
operatively interposed said floor and room sub-modules in said
module, placing and holding said room sub-module in vertical
compression.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent
Application Ser. No. 61/191,694, filed Sep. 10, 2008, for "A
Hierarchical-Autonomy, Footprint-Independent Building Insert Module
System and Methodology". The entire disclosure content of that
provisional application is hereby incorporated herein by
reference.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] This invention--multi-faceted in nature--pertains to
plural-story, steel column and beam building structure, and in
particular, to structure and methodology associated with the
making, transporting, and installing into such a structure of what
is referred to herein as a building-insert module, or as an
in-place room infrastructure--a unit which includes a prepared,
pallet-like floor sub-module which supports an integrated room
sub-module. The room sub-module may be all, or only a part, of a
completed room structure, such as a bathroom, utility room or
kitchen. Depending upon, and appropriately associated with, the
particular design of building in question, the floor sub-module
portion of the proposed module is fabricated so as to have a
generally planar construction which substantially matches (in
plane, and perhaps also in certain basic component structure), and
which is directly integratable in a "seamless" manner with, the
building's pre-designed, directly adjacent floor structure.
[0003] One aspect, or facet, of the invention relates to
preliminary, relative-size design-freedom considerations that are
associated, hierarchically, with concepts of footprint-independence
in two specific areas, or levels, involving the proposed module
structure. One level of such independence involves the invention
feature that the perimetral footprint of a module's room sub-module
may have both positional and dimensional independence of the
perimetral footprint of the associated floor sub-module, except for
the fact that the footprint of the room sub-module will normally
always be fully, and appropriately, "under-supported" by the
"footprint area" of the floor sub-module.
[0004] A second, hierarchical level of footprint independence is
that the perimetral footprint of a module's floor sub-module may,
in both size and position, be independent of the specific
grid-configuration "footprint" of the horizontal beam
arrangement--a rectangle perimetered by four beams connected to
columns--which defines a floor in a building frame. In other words,
the size and configuration perimetrally of a module's floor
sub-module need not particularly fit in any certain matching way
with the usual, rectangular-grid footprint of beams deployed
between columns on a floor level in a building frame.
[0005] Preferably, each floor sub-module includes suitably
configured steel perimeter structures, such as angle-iron-formed
structures, provided both to accommodate integration of that
sub-module with adjacent, conventional, non-module floor structure,
and for enabling anchoring, as by weld-attaching, of the associated
module to selected beams in a frame at desired locations on a floor
in the frame. Such anchoring, in cooperation with the mentioned
perimeter configuring, positionally stabilizes a module in a
column-and beam frame structure in a manner which allows for the
subsequent construction (typically including the pouring in place
of concrete) of adjacent floor structure in a manner to become
co-planar and "seamlessly" coextensive with the structure of the
module's floor sub-module.
[0006] Those skilled in the art will recognize that the just
outlined, two, hierarchical, levels of footprint independence offer
a great deal of design versatility in the thinking lying behind
preparations for the construction of a plural-story building, and
that therefore this footprint-independence "offering" is an
important and notable feature and contribution of the invention.
Such hierarchical footprint independence, in the sense of offered
versatility, clearly decouples (a) room sub-module footprint
dimensions from supporting base pallet footprint dimensions, and
(b) pallet footprint dimensions from receiving building-frame
beam-grid dimensions.
[0007] On another level, the invention involves a unique
staged-assembling, transporting and delivering methodology, wherein
each module is constructed under controlled, precision, factory
conditions, with the assembly sequence featuring preassembly of
that module's floor-sub-module which thereafter acts as a
supporting pallet for the then, still-to-be-constructed room
sub-module. From that point on, and throughout the subsequent
completion of construction, delivery and installation of the
associated module, the floor sub-module retains the role of a
supporting pallet.
[0008] Thus, one can imagine something like an initial,
assembly-line process, wherein a module's floor sub-module is first
built, and then, as appropriate, moved as from construction station
to construction station, if that is the building approach which one
chooses to use, for the implementation of subsequent room
sub-module, module-assembly steps. For example, in a typical
practice of the invention, a precursor, floor sub-module "pallet",
which includes a steel perimeter frame (preferably though not
necessarily selectively oriented angle iron components), a
frame-spanning, corrugated steel web expanse, and over this web
expanse a thin, poured, concrete floor, are first prepared.
Thereafter, and to complete module construction, on this prepared
pallet, the upright framing, wall structures, internal surface
finishing, internal appliances, fittings, equipment, etc.,
including, if desired, wall-carried, pre-established electrical and
fluid infrastructure, are built/applied, as by an assembly-line,
factory process in any appropriate manner.
[0009] At the completion of module assembly, the floor sub-module
in a module acts then acts as a transporting pallet for the module,
and later on, also as a supporting pallet through which a lifting
force may be employed at a building-frame construction site for the
picking up, moving and placing of the module at the correct
location within a building frame under construction. As was
mentioned earlier, the floor sub-module portion in each module
prepared for insertion into a building frame of a particular design
is constructed so as to be substantially like, and fully compatible
with, what will, after module insertion and preliminary
installation, become the constructed, adjacent floor structure in
the building.
[0010] Yet another important feature and facet of the methodology
and structure of the present invention is module-internal
compression involving the employment of elongate, upright tension
rods, also used as lifting and handling "pick" rods, which are
installed within and become part of each module as post-pallet,
room-sub-module construction is undertaken. These rods have their
bases anchored in the associated floor sub-module (the pallet), and
extend upwardly therefrom to exposed, threaded, upper ends which
project upwardly from upper portions of the associated room
sub-module. Through these rods, near the completion of the assembly
of a module, via nuts which are threaded onto the rods, tension is
developed at an appropriate level in the rods to produce an
internal, "module-specific" compression in the included
room-sub-module--a compression which plays several important roles
in the preferable implementation of this invention, and which
preferably remains as a permanent feature of each module even after
in-building installation.
[0011] In this context, the rod-tension/room-sub-module-compression
which is thus introduced is such that, when a module is lifted
through the rods--acting then as "pick" rods--tension is relieved,
or relaxed (reduced) somewhat in the rods, but not to the point
where compression in the room sub-module disappears. In other
words, the associated room sub-module always remains in a state of
compression, whereby, among other important consequences,
room-finishing details, such as wall-surface details (like paint,
wallpaper, etc.), when a module is lifted to be placed within a
building frame, do not go into tension, and more specifically, are
not allowed to enter a tension-stress condition wherein fissures
and fractures and other forms of handling-deformation damage may
take place. Accordingly, these pre-stressed, tensioned rods, which
extend in a module from the floor sub-module pallet upwardly
through, and to the top structure of the pallet-carried room
sub-module, pre-load the entire room sub-module unit so as enable
it to be picked up without such picking-up introducing damaging
deformation strains into finished room structure geometry and
internal features during transport movement of a module, and
ultimate placement thereof into the appropriate location in a
building frame structure.
[0012] Additionally, the employment of tension rods as described to
introduce pre-compression into the room sub-module portion of a
module effectively freezes and stabilizes the entire associated
module into a state of high resistance to any seismic, or
seismic-like, loads particularly during the stage of employment of
a module where that module is being placed and initially anchored
in place in what, at that point in time, will be an unfinished
building structure.
[0013] Another very important feature of the present invention
which is related directly to the employment of
compression-introducing tension rods as just above described, is
that, when a module has been placed at its desired location in a
building frame, and ultimately when that module becomes integrated
with other structure in a building, and recognizing, as has been
stated above, that the condition of room sub-module compression is
permanently retained, within an overall building structure
containing modules constructed in accordance with the present
invention, these modules function as internally,
independently-self-stabilized "nuggets" of seismic-damage
resistance--significant nuggets of such resistance that are
completely independent of whatever "higher-level" seismic-damage
resistance may be built into the associated, principal building
frame structure per se. Thus, in, for example, a full-moment-frame
building structure which is typically robustly resistant to seismic
damage, within that structure, in accordance with the present
invention, internally contained modules are further protected
against seismic damage by virtue of the fact of their independent,
compressively pre-stressed and pre-loaded stabilization.
[0014] These and other important and unique features and advantages
which are attained and offered by the present invention will become
more fully apparent as the description which follows below is read
in conjunction with the accompanying drawings.
DESCRIPTIONS OF THE DRAWINGS
[0015] FIG. 1 is a fragmentary, two-vanishing-point, downwardly
looking, and somewhat simplified, perspective view of several,
above-ground-level stories, or floors, in an open,
under-construction, plural-story main, column-and-beam building
frame in which have been installed, as shown, several
building-insert modules made and handled in accordance with the
structure and methodology of the present invention.
[0016] FIG. 2 is an enlarged, fragmentary cross-sectional view
taken generally along the line 2-2 in FIG. 1.
[0017] FIG. 3 is a greatly simplified, schematic,
"fabrication-stage" drawing illustrating the making of a module in
accordance with the methodology of the present invention.
[0018] FIGS. 4 and 5 are greatly enlarged, common-scale,
fragmentary, cross-sectional views taken generally along the lines
4-4, and 5-5, respectively, in FIG. 3.
[0019] FIG. 6 is an enlarged, fragmentary view taken generally in
the area in FIG. 3 which is partly encircled by the curved arrow
numbered 6. This view shows an upper portion of a tensioning
structure which is preferably employed in modules made in
accordance with the present invention.
[0020] FIG. 7, which is drawn on a larger scale than that employed
in FIG. 6, presents a fragmentary, cross-sectional elevation taken
very generally in the area in FIG. 3 which is partly encircled by
the curved arrow numbered 7. This figure illustrates, effectively,
the lower portion of the tensioning structure which is partially
illustrated in FIG. 6.
[0021] FIG. 8 is a simplified, relatively small-scale elevation
illustrating a tractor-trailer vehicle loaded for the delivery to a
building site of several modules (three) made in accordance with
the present invention.
[0022] FIG. 9 is a high-level schematic, plan illustration
describing visually what are referred to herein as
footprint-independence hierarchy features of the present
invention--features that interrelate a beam-grid footprint in a
building frame, a module floor sub-module footprint, and a module
room sub-module footprint.
[0023] FIG. 10 is a simplified and schematic, fragmentary,
isometric illustration picturing the practice, according to the
present invention, of lifting from a building-site staging area,
and then maneuvering, placing and installing modules made in
accordance with the present invention at different locations, on
different stories or floors, in an open, under-construction,
column-and-beam main building frame, like the building frame which
is pictured in FIG. 1.
[0024] Regarding all of these drawing figures, it should be
understood that relative dimensions and proportions that are
employed are not necessarily presented to scale.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Turning now to the drawings, and referring first of all to
FIG. 1, indicated generally at 20 is a fragment of an open,
plural-story (plural floor level) building main frame (or building
structure) formed of upright, steel columns 32 and principal,
horizontal, steel beams 24, the latter being arranged in a
conventional, rectangular-footprint, such as grid (or beam-grid)
footprint 26, whose sides and perimetral outline are defined by
four beams 24, and whose corners are defined by four columns 22. As
can be seen in this figure, beam-grid footprint 26, also referred
to herein as a story pane, is indicated by an arrow-headed
reference lead line at the upper left part of the figure pointing
to an open rectangle of four, fully visible beams 24.
[0026] Installed in place, as will shortly be explained, in frame
20, in accordance with a preferred and best-mode implementation of
the invention, is a system shown generally at 21 featuring at least
one, but herein a plurality of, pre-fabricated building-insert
module(s), six of which appear variously in FIG. 1. The structures
and natures of these modules will be described in text which later
follows.
[0027] The columns and principal beams in frame 20 are
interconnected at nodes of interconnection, such as nodes 28,
through appropriate, full-moment connections, such as the
connections described in U.S. Pat. No. 6,837,016. These nodal
column/beam connections, whose details form no part of the present
invention, are illustrated herein only as simple (i.e.,
undetailed), column-side, beam-end nodal intersections. The fact
that these connections are full-moment connections, however, is
relevant to one performance-capability facet of one particular
embodiment of the invention. The disclosure content of the
just-identified '016 U.S. patent is hereby incorporated herein by
reference.
[0028] Frame 20, which is illustrated in an open (as mentioned),
under-construction condition, includes plural, above-ground floors
(or stories) such as floors 30, 32, 34. Floors 30, 32, 34 are also
referred to herein as story levels.
[0029] At appropriate design-determined locations at the
common-floor (30, 32, 34) principal beam levels in these respective
floors, auxiliary beams, such as the two shown partially (each) at
36, may optionally be installed to extend between two other beams,
such as between two principal beams 24. Such auxiliary beams, where
employed, cooperate with the principal beams to furnish
under-support for overhead structure, such as for a main building
floor structure 38 (a conventional under-floor structure which does
not form any part of the present invention), and, among other
things, also for modules made and installed in accordance with the
system and methodology of the present invention--three of such
modules, each of which is also referred to herein as an in-place
room infrastructure, being indicated generally at 40, 42 on floor
30, and at 44 on floor 34. Each of these modules is in place in
frame 20 in a partially completed, earlier pre-fabricated state,
with module 40 being specifically pictured in a state possessing
somewhat more included wall structure than that present in the
other, five, illustrated modules, simply to illustrate the fact
that modules according to the present invention may be installed in
a building frame in different conditions of "initial" module
completion.
[0030] Before turning detailed attention toward module-structure
(and associated aspects of the present invention), a
building-floor-structure matter to note in FIG. 1, viewed now along
with the left-side portion of the cross-sectional illustration
presented in FIG. 2, is the nature of certain aspects of main
building floor structure (really an under-floor structure) 38. This
under-floor structure (recognizing that many, different, specific
and conventional types of under-floor structure could be employed)
is formed herein with appropriately, differently sized
(perimetered) horizontal panels 46. Each panel 46 includes a
corrugated, horizontal steel expanse 48 which extends essentially
to the perimetral edges of the panel, and distributed over this
expanse, and over adjacent panels and their respective panel
expanses 48, in a panel-to-panel "bridging" fashion, poured
concrete 50, shown fragmentarily on floor 34, which produces a
smooth-topped, common-plane, substantially overall "sub-floor" for
the usual, later "finishing" installation of a more "dressy"
over-floor structure (not shown). The elongate corrugations in
different panel expanses 48 may be oriented with their long axes
extending either in relative orthogonal, or in common, directions,
as appropriate.
[0031] Turning now to the structures and features of the
building-insert modules of this invention, and to associated module
fabrication, handling and installation methodology, and referring
initially and specifically to module 40, this module will be
treated herein as being illustrative of the basic constructions of
all of the modules proposed by the present invention,
notwithstanding the fact that module 40, as was mentioned above,
possesses a slightly greater degree of initial pre-fabrication
completion in relation to the five other modules illustrated, for
example, in FIG. 1. Accordingly, each module includes two, main
portions, or sub-modules, including, as seen for module 40, a
substantially planar floor sub-module 52, also referred to herein
as a pallet, and a partially completed, three-dimensional room
sub-module 54. Room sub-module 54 is appropriately anchored to, and
rises upwardly from, the upper, generally planar surface 56 of the
associated floor sub-module, 52. In the particular systemic
embodiment of the present invention which is now being described,
and simply for representative illustration purposes herein, each of
the modules pictured in FIG. 1 is designed with pre-installed
equipment, etc., for making up portions of a bathroom and portions
of an adjacent kitchen. This condition of these modules is made
clearly evident in FIG. 1. Those skilled in the art will readily
appreciate that other kinds of room characters could easily be
formed in the modules of the invention.
[0032] Adding attention now to FIGS. 3-7, inclusive, in addition to
FIGS. 1 and 2, for an extended discussion surrounding the modules
of the present invention, and beginning with FIG. 3, here there is
illustrated, in very simple, high-level schematic-sequence form, a
fabrication staging process which is uniquely proposed by the
present invention for module construction and early handling.
Keeping module reference numerals, and succession thereof, now
employed in FIG. 3 compatible with the small amount of predecessor
reference numerology employed so far with regard to module 40 in
FIG. 1, FIG. 3 will be used illustratively to explain, generally,
the basic fabrication methodology and chronology associated with
this particular module. FIGS. 4-7, inclusive will be brought in, as
appropriate, in support of FIG. 3 to describe in more detail module
structural features which develop during module fabrication.
[0033] Regarding what is shown in these several drawing figures,
and especially in FIG. 3, an "emerging" module, numbered 40, is
there pictured in very simple and idealized, full-rectangular form,
including, ultimately in "module-completed" condition on the right
side of the figure, a planar floor sub-module 52 having a
square-rectangular configuration, or footprint, of one size, and a
generally square-rectangular room sub-module 54 (on floor
sub-module 52) possessing four walls intersecting at four "normal"
corners, and having a smaller size, square-rectangular
configuration, or footprint, which is offset, or non-centered,
laterally with respect to the footprint of the floor
sub-module.
[0034] Accordingly, at the beginning of module construction, the
first thing to occur is the formation of floor sub-module 52,
including the providing therein of all structure which will be
necessary to support, and work with, the subsequently
to-be-fabricated room sub-module 54. As was previously mentioned,
floor sub-module 52 has a substantially planar construction which,
in accordance with an important feature of practice of the present
invention, is intended to perform in various ways, and more
specifically, as a supporting pallet throughout (a) the
fabrication, (b) the thereafter transportation to a building-frame
site, and (c) the then ultimate installation into a building frame,
of a module.
[0035] Thus, appearing toward the lower left corner of FIG. 3 is
initially-constructed module floor sub-module 52 which, as was just
mentioned generally above, is illustrated in FIG. 3 in the form of
a relatively simple, basic square. This floor sub-module includes a
generally rectangular perimetral frame 58 which defines the
perimetral configuration and outline of the floor sub-module, and
more specifically, defines for this sub-module what is referred to
herein as a defined floor sub-module footprint. Perimetral frame 58
herein is formed for illustration purposes from four, end-joined,
steel angle-iron components 60, 62, 64, 66, which components define
what is referred to herein as lateral edge structure (with edges)
for floor sub-module 52.
[0036] With respect to these four angle-iron components, components
60, 64, 66 are oriented with one each of their two flanges
occupying an upright plane "banding" a lateral side, or edge, of
the floor sub-module, and with their other, respective, flanges,
in-turned inwardly under these edges on the underside of the floor
sub-module. Component 62, on the other hand, is oriented somewhat
differently, and more specifically, with one of its flanges lying
in an upright plane along an edge in the floor sub-module, and its
other flange extending generally horizontally and laterally
outwardly from that edge.
[0037] These conditions for the mentioned, four angle-iron
components are pictured not only in FIG. 3, but especially well for
components 62, 64 and 66 in FIGS. 4 and 5. A reason for the
somewhat different, outwardly-flange-projecting disposition
provided for angle-iron component 62 is that this disposition makes
the outwardly-turned flange in this component available as a
support shelf for assisting in lateral, welding (or other) joinder
with appropriate steel structure furnished adjacent the edge of a
building floor panel 46, as is illustrated, and as will later be
more fully explained, in and with respect to FIG. 2 in the drawings
which illustrates such joinder in relation to the floor sub-module
which forms part of module 44.
[0038] As was mentioned, floor sub-module 52 is prepared to include
suitably all structure which is necessary for the subsequent
anchoring to it of still-to-be-fabricated room sub-module 54. In
order to maintain simplicity in the drawings, and yet to focus
attention importantly on another significant facet and feature of
the present invention which involves such "anchoring" structure,
illustrated schematically at the left side in FIG. 3 in the
drawings, with respect to the stage of module fabrication which
involves the making of floor sub-module 52, are four, upwardly
extending, elongate, threaded tensioning rods, or tensioned
structure, 68, three of which rods are illustrated only
fragmentarily in the FIG. 3, and one of which is illustrated in
full length, capped at its upper end by a module-lifting eyelet 70
(to be further discussed later herein).
[0039] These tensioning rods are also referred to herein as
module-specific force-applying structure, and the rods, along with
eyelets 70, are collectively referred to as pick structure.
[0040] Continuing with a description of the construction of floor
sub-module 52 as illustrated herein, suitably joined, as by
welding, inwardly of, and spanning the area bounded by, the four
angle-iron components that define the perimeter structure in the
floor sub-module, is a corrugated expanse of sheet steel 72 (see
particularly FIGS. 4, 5 and 7), with the long axes of these
corrugations in the particular floor sub-module now being described
being shown at several locations at 74 in FIGS. 4, 5 and 7.
[0041] Formed as by pouring over corrugated expanse 72, and within
the bounding structure furnished by the four angle-iron components,
is a concrete floor body, or simply concrete, 76 which has a
smooth, substantially planar, upper surface 78.
[0042] The previously mentioned, but not fully illustrated,
structural components which are furnished within floor sub-module
52 to promote and support overhead anchoring of the
soon-to-be-fabricated, overhead room sub-module 54, are preferably
suitably anchored within the "volume" of the floor sub-module,
captured either by attachment to a portion of steel corrugated
expanse 72, and/or additionally captured by concrete 76. With
reference made for a moment to FIG. 7, here one can see that the
lower end of each tensioning rod 68, such as the one here shown, is
fitted with an anchoring component 80 which is embedded in concrete
76.
[0043] Continuing with the high-level, module-fabrication
description now being given in relation to FIG. 3, a broad arrow 82
represents transitioning of completed floor sub-module 52 to the
next, sequential stage(s) for follow-on fabrication of overhead
room sub-module 54. Significantly, floor sub-module 52 functions
here and now as a fabrication-handling pallet for the entire
remainder of the module-construction process. Two, nominally
rectangular walls 84, 86 are pictured centrally in FIG. 3 to
represent undergoing construction of the mentioned room sub-module.
Specific, room sub-module infrastructure, such as bathroom, kitchen
or other infrastructure is not pictured, and is not important to an
understanding of the methodology of the invention. In an actual
fabrication procedure, of course, appropriate infrastructure of the
nature just generally indicated would be installed at the
appropriate time(s) during module fabrication.
[0044] In relation to what is shown centrally in FIG. 3, it should
be noted that the earlier-mentioned placement of tensioning rods 68
has been done with respect to the defined footprint of floor
sub-module 52, whereby these tensioning rods will extend
appropriately upwardly through, for example, wall structure to be
constructed in the associated, overhead, room sub-module. With
respect to walls 84, 86, three of these tensioning rods 68 are
pictured in dashed lines included at appropriate "corner" locations
within those walls, with the associated lifting eyelets 70 disposed
free and clear above the walls. The fourth tensioning rod 68 is, in
the central portion of FIG. 3, shown only fragmentarily.
[0045] A broad arrow 88, which is somewhat like previously
mentioned arrow 82, indicates transition handling of what is now a
substantially completed room sub-module 54 (on floor sub-module 52)
to a final stage in the fabrication sequence which is pictured on
the upper right side in FIG. 3. Accordingly, room sub-module 54 is
here shown completed as a simple cube, with two more rectangular
walls 90, 92 now in place, and with all of the four, relevant,
previously installed, tensioning-rod-connected, lifting eyelets 70
clearly pictured at elevations above the completed walls in the
room sub-module.
[0046] One thing to note particularly with what is illustrated
especially at the upper, right-hand corner of FIG. 3 is that what
may be thought of as the defined footprint of room sub-module 54--a
rectangle, or square--is truly completely independent of the
defined footprint of associated floor sub-module 52. More
particularly, in relation to the simplified showing of module 40
which appears in FIG. 3, the defined footprint of room sub-module
54 is both smaller than, and contained within, the lateral
boundaries of the defined footprint of floor sub-module 52, with
the room sub-module being located for representative illustration
purposes laterally off-center on floor sub-module 52, and
specifically disposed toward one corner of the defined, generally
rectangular floor-sub-module footprint.
[0047] Referring especially now to FIGS. 3 and 6, threaded/placed
onto the upper exposed ends of tensioning rods 68 are appropriate
nut and washer assemblies, like the one shown at 94 in FIG. 6.
These assemblies effectively rest herein directly on, or otherwise
indirectly, bearingly vertically upon, the upper portions of
appropriate upper wall frame members, such as frame members 96, 98
in walls 90, 92, respectively. Assemblies 94 are employed to be
tightened on the associated, receiving tensioning rods to produce,
generally as indicated by the arrows 100 appearing in FIGS. 3 and
6, a user-selected level of vertical compression in the associated
room sub-module.
[0048] Purposes for this established compression include, inter
alia, (a) assuring that when the associated module is picked up,
the room sub-module therein will not go into tension, so that, for
example, any "delicate" wall-surfacing materials (or other
tension-at-risk materials/structures) will be protected against
cracking/fracture/etc. damage, and also (b) to assure that, as the
overall module is handled and moved, and when thereafter the module
has been placed at the desired location within a building frame,
such as within building frame 20, it is and will be continuously
stabilized against potentially damaging deformations which might be
caused by any form of jostling, such as might be produced by a
seismic event. Once installed within a building frame, such
compression stabilization is preferably retained so as to produce a
situation wherein an installed module, and its sub-modules
(particularly the room sub-module), possess a protective stability
which is completely independent of that present in any other
surrounding structure, including, as an illustration, a receiving
moment-frame structure. A significant consequence of this condition
is that a building-insert module constructed, handled, and
installed in a building frame, in accordance with the present
invention, is internally guarded with dimensional stability and
robustness, all enhanced, of course when combined with the native
stability of a receiving building frame which naturally possesses
it own inherent stability security.
[0049] Those skilled in the art will understand quickly how to
assess what level of compression to introduce into a room
sub-module simply by taking into account the lifting force which
will be necessary to pick up the associated module, and by
establishing a compression level whereby when that lifting force is
applied, and there is no longer any underlying support, such as
ground support, for the associated module, a certain amount of
vertical compression, which is completely user pre-determinable,
will remain in the room sub-module structure so as to prevent that
sub-module from entering a state of vertical tension.
[0050] On a related point, experience has shown that when such a
"tension-inhibiting" level of compression is introduced into a room
sub-module, that level of compression affords an adequate measure
of room-sub-module stabilization, though it is certainly recognized
that a practicer of the present invention might choose, if desired,
to introduce an even greater level of compression.
[0051] When module fabrication has been completed, and a collection
of modules that are intended to be installed in a particular
building frame, such as in building frame 20, is readied for
delivery, the included modules are appropriately picked up and
placed on a transport structure, such as on the trailer in the
tractor-trailer vehicle which is shown generally at 102 in FIG. 8.
Here, three completed modules 104, 106, 108 are shown on the
trailer section of tractor-trailer 102. During module transport,
the floor sub-module in each transported module functions
conveniently, according to the invention, as a transport pallet for
the associated module.
[0052] At the appropriate building site, such as the building site
shown generally at 110 in FIG. 10, delivered modules, such as
just-mentioned modules 104, 106, 108, are placed appropriately in a
ground staging zone, such as the staging zone, also referred to
herein as a building-frame-insertion staging site, indicated
generally at 112 in FIG. 10, from which zone a machine, such as a
crane (not shown) having lifting cable structure like that shown
generally at 114, may be used to pick up (pick) and move the
relevant modules to their assigned places in a building frame shown
at 116 in this figure. Frame 116 is like previously mentioned frame
20 shown in FIG. 1. In order to relate what is now being described
about module handling at a building site to what appears in FIG. 1,
crane cable structure 114 is also shown in FIG. 1, attached to
eyelets 70 associated with module 40.
[0053] Further describing FIG. 10, such a picking, moving and
placing operation is schematically illustrated in this figure for
module 104 which is illustrated in three different positions in the
figure--(1) on the ground in zone 112, (2) lifted (see arrow 118)
by crane cables 114 (which are attached to lifting eyelets 70) to
an elevation above the ground but outside frame 116, (3)
appropriately laterally shifted (see arrow 120), and then (4)
lowered, as indicated by arrow 122, to the appropriate
building-floor location intended for it in frame 116.
[0054] It will be immediately evident that during this
building-site installation procedure as generally illustrated in
FIG. 10, the floor sub-module portions of each module, such as the
floor sub-module portion of module 104, through the operative
connections which exist therewith through the tensioning rods and
the lifting eyelets of the mentioned pick structure, act as
lifting, and installation-handling, pallets for their respective
modules--another useful feature of the present invention.
[0055] Returning attention now for a moment to FIG. 2, this figure
helps to explain an important feature of the invention which
involves the fact that, preferably, the floor sub-module structure
in each module which is intended to be installed in building frame
20 is constructed with a corrugated steel expanse and an overlying,
poured distribution of concrete which construction substantially
matches the same kind of construction employed in each building
floor (or building sub-floor) panel 46. When a module is properly
installed in place in frame 20, and when thereafter surrounding
building floor panels 46 are installed, and concrete for and over
the sub-structures in these panels appropriately poured, the
building frame floor panels (46) lie substantially coextensive and
coplanar with the floor sub-modules in modules present on each
common floor level in the building frame.
[0056] This condition is precisely what is illustrated
(fragmentarily) in FIG. 2, where the illustrated building floor
panel 46 lies immediately adjacent the floor sub-module, shown at
124, in module 44, which floor sub-module includes an angle-iron
perimeter frame 126, a perimeter-frame-spanning expanse of
corrugated steel 128, and a poured body of concrete 130 overlying
expanse 128, and disposed within perimeter frame 126. This
structural situation produces a substantially coplanar condition
for the upper, smooth surfaces of all of the building floor panels
and all of the module floor sub-modules that exist on a given floor
in frame 20. Such a common plane is illustrated by a dash-dot-line
132 in FIG. 2.
[0057] Turning attention finally to FIG. 9 the in the drawings,
here there is indicated very generally at 134 a schematic, plan
illustration of another one of the important features of the
invention--the feature which involves the fact that there is
substantial dimensional and configurational independence between
the three kinds of defined footprints which have been described and
discussed above herein. More specifically, there is a specific
independence which exists between the so-called beam-grid footprint
in a building frame, such as previously described beam-grid
footprint 26, and the defined footprints (not necessarily all the
same) of the floor sub-modules in modules which are to be employed
in such a frame. Additionally, there is a similar, specific
independence between the defined floor sub-module footprints of a
module and the defined footprints (also not necessarily all the
same) of associated room sub-modules included in the same
modules.
[0058] The significances and special utility of this hierarchical,
footprint independence has been explained earlier herein.
[0059] In FIG. 9, a beam-grid footprint is defined by the four
solid lines 136, 138, 140, 142 which appear in this figure.
[0060] Two differently configured and differently sized, defined
module floor sub-module footprints are shown respectively by a
solid-line square 144, and by a dash-dot-line rectangle 146. The
relative dispositions of these two floor sub-module footprints in
FIG. 9 helps to illustrate the beam-grid-footprint/module-footprint
substantial independence just mentioned.
[0061] Within floor sub-module footprint 144, two, different,
defined room sub-module footprints are illustrated, with one being
shown by a solid-line rectangle 148, and the other being shown by a
dash-double-dot-line rectangle 150. As can be seen, these two room
sub-module footprints differ in size and configuration, and are
positioned relative to one another in FIG. 9 at different locations
over defined floor sub-module footprint 144.
[0062] The discussions presented herein regarding the several
footprint independences which are featured by the present invention
should be understood in the context that such independences may
take on a wide variety of relative characteristics depending upon a
user's wishes and resulting building design. Accordingly, no
specific, relative independence regarding different, defined
footprints is dictated by practice of the present invention.
[0063] From a methodologic point of view, what is proposed by the
present invention, generally expressed, is a building-insert module
methodology associated with an open building frame which is defined
by columns and beams, with this methodology including the steps of
(a) creating a prefabricated module structure including (1) a floor
sub-module having an upper surface, and (2) an at least partially
completed, three-dimensional room sub-module anchored to and rising
upwardly from the upper surface of the floor sub-module, with the
created floor sub-module performing as a fabrication pallet for the
creating of the room sub-module, (b) transporting the created
module to a building-frame-insertion staging site located adjacent
such a building frame, using the module's floor sub-module as a
transport pallet, and (c) from the mentioned staging site, lifting
the thus transported module and inserting it into a selected
location within the frame using the module's floor sub-module as a
lifting pallet.
[0064] In a more specific sense, this methodology further includes,
following creation of the mentioned room sub-module, placing that
sub-module in a condition of vertical compression, and even more
specifically, creating this condition of vertical compression
utilizing tensioned pick structure which forms part of the created
module, and implementing such vertical compression to a level which
will not allow the room sub-module to enter a state of vertical
tension during free lifting of the associated module.
[0065] Accordingly, a preferred and best-mode embodiment, and
manner of practicing, the present invention have been described and
illustrated herein, with certain modifications and variations
specifically mentioned and/or suggested, and it is intended that
the following claims to invention will be construed to include all
of that described and suggested subject matter, as well as all
modification subject matter which may naturally come to the minds
of those generally skilled in the relevant art.
* * * * *