U.S. patent application number 17/279318 was filed with the patent office on 2021-12-23 for modular construction system.
The applicant listed for this patent is Corner. Invention is credited to Ludovic Lachavanne, Guillaume Largillier.
Application Number | 20210396002 17/279318 |
Document ID | / |
Family ID | 1000005882183 |
Filed Date | 2021-12-23 |
United States Patent
Application |
20210396002 |
Kind Code |
A1 |
Largillier; Guillaume ; et
al. |
December 23, 2021 |
MODULAR CONSTRUCTION SYSTEM
Abstract
A construction assembly for a prefabricated building, comprises
horizontal elements and vertical elements as well as assembly
elements. The horizontal, vertical and assembly elements are formed
by a first panel forming one of the longitudinal faces, a second
panel forming a structuring layer on the opposite longitudinal
face, and an insulating layer disposed between the longitudinal
faces. The thickness U of the vertical elements corresponds to the
cross-section of the assembly elements, the length of the vertical
elements is a multiple of U, and at least some of the assembly
elements further comprise fluid pipes and/or electrical
cabling.
Inventors: |
Largillier; Guillaume;
(Cenon, FR) ; Lachavanne; Ludovic; (Cenon,
FR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Corner |
Cenon |
|
FR |
|
|
Family ID: |
1000005882183 |
Appl. No.: |
17/279318 |
Filed: |
September 24, 2019 |
PCT Filed: |
September 24, 2019 |
PCT NO: |
PCT/FR2019/052231 |
371 Date: |
March 24, 2021 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 1/30 20130101; E04B
1/1909 20130101; E04B 1/14 20130101; E04B 1/34331 20130101 |
International
Class: |
E04B 1/343 20060101
E04B001/343; E04B 1/14 20060101 E04B001/14; E04B 1/30 20060101
E04B001/30; E04B 1/19 20060101 E04B001/19 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 24, 2018 |
FR |
1858639 |
Claims
1. A construction assembly for a prefabricated building,
comprising: horizontal elements and vertical elements as well as
assembly elements, wherein the horizontal, vertical and assembly
elements are formed by a first panel forming a longitudinal face, a
second panel forming a structuring layer on the opposite
longitudinal face, and an insulating material disposed between the
longitudinal faces, a thickness U of the vertical elements
corresponding to a cross-section of the assembly elements, the
length of the vertical elements being a multiple of U, and at least
some of the assembly elements further comprising fluid pipes and/or
electrical cabling.
2. The assembly of claim 1, wherein at least some of the elements
have male connectors inserted at regular intervals on a rim of the
elements, and female connectors inserted symmetrically and facing
the male connectors on the corresponding rims.
3. The assembly of claim 2, wherein the rim of the assembly
elements is machined at each insertion point of a female connector
to create a trench at the bottom of which the female connector is
housed.
4. The assembly of claim 3, wherein the trench is wider on the edge
of the rim of the assembly element to facilitate the insertion of
the male connector.
5. The assembly of claim 1, wherein a lower structural part of the
assembly elements comprises a bracket reinforced by a metal profile
of rectangular cross-section defining a pipe for ventilation of
air.
6. The assembly of claim 5, further comprising orifices formed
regularly along inner faces of the profile.
7. The assembly of claim 6, wherein the orifices pass through the
bracket.
8. A method constructing a prefabricated building, comprising the
following steps carried out successively: installing one or more
horizontal modules to form a floor, connecting a network of lower
beams on all side faces of at least one horizontal module,
elevating vertical walls by connecting a series of vertical modules
and posts on an upper face of the lower beams, placing a second
network of horizontal beams to which horizontal panels will
ultimately be connected in order to compose a roof or an upper
level.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national phase entry under 35 U.S.C.
.sctn. 371 of International Patent Application PCT/FR2019/052231,
filed Sep. 24, 2019, designating the United States of America and
published as International Patent Publication WO 2020/065198 A1 on
Apr. 2, 2020, which claims the benefit under Article 8 of the
Patent Cooperation Treaty to French Patent Application Serial No.
1858639, filed Sep. 24, 2018.
TECHNICAL FIELD
[0002] The present disclosure relates to the field of the modular
construction of prefabricated buildings, and more particularly to a
construction assembly comprising a network of posts and beams
allowing the arrangement and maintenance of vertical and horizontal
walls, and some of which also integrate means for the circulation
of fluids. At least part of the walls consist of SIF-type panels
(structural, insulated, finished). The cross-section of the beams
is substantially equal to the cross-section of the SIF panels.
[0003] The present disclosure relates to the field of the
construction of buildings [IPC/EPC E04B], and, in particular, of
small-scale buildings such as individual houses, grouped housing,
offices, schools and other collective facilities (nursery,
community centers, etc.).
[0004] The present disclosure relates more particularly to the
field of off-site building construction.
[0005] Such constructions reduce the time, the costs and the risks
linked to the site and also have a positive impact on the
environment by limiting the nuisances caused by the construction
(noise, pollution, logistics).
[0006] The present disclosure also relates to the field of the
construction of buildings with high energy and environmental
performance, in particular, those meeting low consumption building
standards (as defined, in particular, by standards RT-2012, RT
2020, Passivhaus). Such buildings are characterized primarily by
low energy consumption obtained by optimizing thermal insulation,
moisture and air tightness, ventilation and thermal inertia.
[0007] In the context of this patent, the terms below will be
interpreted as follows: [0008] Off-site construction: designates a
construction method consisting in constructing all or part of a
building outside its installation site, for example, in a workshop
or a factory, as opposed to traditional on-site construction, which
consists in transporting the various materials to erect the
structure of the building on its site. [0009] Modular construction:
construction carried out by assembling elements (modules) that are
prefabricated in the factory, possibly allowing the reuse and
serial replication of the elements. [0010] "3D" modular
construction: modular construction made up of volumes that are
partially or totally prefabricated and pre-assembled in the
factory, then transported and installed on site; [0011] "2D"
modular construction: modular construction made up of surface
elements or (panels: floors, walls, roofs, partitions) that are
prefabricated in the factory and assembled on site; [0012]
Construction in kit form: construction on site from elements
pre-cut in the factory. [0013] Sandwich panel: panels made up of
different layers. [0014] SIP panels ("Structural Insulated Panel"):
sandwich panels comprising at least one structural layer and one
insulating layer; [0015] SIF panels ("Structural Insulated
Finished"): SIP-type sandwich panels further including
interior/exterior finishes; [0016] Fluids (Circulation
of/Management of): refers to the means assigned to the management
of non-solid elements of the building (water, electricity, gas,
air). Generally, fluids comprise plumbing (supply, discharge of
wastewater and rainwater), heating and ventilation, distribution of
energy sources (gas and electricity). [0017] Thermal inertia:
capacity of materials to maintain their temperature. [0018] Phase
shift: ability of materials to retard temperature variations.
[0019] Hygrometry: quantity of water vapor in the air, ambient
humidity.
BACKGROUND
[0020] French patent FR2610655 is known, which describes a known
solution of a metal frame characterized in that it is constituted
with a minimum of vertical posts, that is: at least four,
incorporated in the corners, associated with metal profiles
embedding the base of the panels, while the upper part of the
panels is reinforced by metal inserts bolted to specific parts
allowing the fixing of the lower ends of the trusses supporting the
roof. This metal frame can be completely dismantled, while being
largely hidden in the sandwich panels, either during the
manufacture of the latter, or during assembly (like the corner
posts).
[0021] U.S. Pat. No. 6,931,803 is also known describing a solution
consisting in using a post-beam structure. The solidity of the
construction is ensured by the fixing of the posts and beams. The
walls do not play a structuring role here and can therefore be
freely formed from any type of panel, in particular, sandwich-type
panels as described above. This document of the prior art thus
describes a method for implementing panels by means of extruded
plastic beams making it possible to connect the vertical and
horizontal elements. However, this document does not disclose any
teaching enabling a person skilled in the art to integrate the
circulation of fluids.
[0022] Patent application WO2012021055A2 describes a system
comprising a plurality of building elements characterized by a
hollow bar as a connecting means for connecting pillar assemblies
and an engagement means for connecting pillar and wall assemblies.
The system further comprises a column for forming pillar assemblies
and a wall panel for forming wall assemblies. A first beam supports
a floor and a second beam supports ceiling assemblies that comprise
a junction plate on a first end and a second end for engaging the
engagement means. A flat panel that forms a floor in the building
comprises a plurality of supports for receiving penetrant.
[0023] The solutions of the prior art using structural insulated
panels have the drawback of weight, cost, size and difficulties in
transporting these structures.
[0024] The main problem with these solutions known in the state of
the art is the complexity of implementation on the site. These
systems do not resolve, or only partially resolve, the technical
complexity of fluid management and finishing, which requires
several months of work once the building is out of water and out of
air. They also require additional procedures, after the assembly of
the superstructure, to install the finishing equipment.
BRIEF SUMMARY
[0025] To get around this problem, those skilled in the art can
turn to 3D modular construction, which involves prefabricating
finished volumes that can, if necessary, integrate the finishing
and the circulation of fluids. This type of prefabricated
construction is extremely limited by the geometric constraints
imposed by transport from the factory to the installation site.
[0026] The object sought by the present disclosure is to
manufacture high-performance houses at a lower cost and in less
time by assembling prefabricated modules on site that integrate all
the necessary elements (structural work, light work,
finishing.).
[0027] For this, it is necessary to solve the following
implementation problems: [0028] Assembly/fixing of the modules
[0029] Fluid circulation [0030] Rainwater runoff [0031] Ventilation
[0032] Electricity (High Current/Low Current) [0033] Water supply
(hot cold/hot) [0034] Wastewater disposal.
[0035] To this end, the present disclosure relates in its most
general sense to a construction assembly for a prefabricated
building comprising horizontal elements and vertical elements as
well as assembly elements, characterized in that the horizontal,
vertical and assembly elements are formed by a first panel forming
one of the longitudinal faces, a second panel forming a structuring
layer on the opposite longitudinal face, and an insulating material
disposed between the longitudinal faces, the thickness U of the
vertical elements corresponding to the cross-section of the
assembly elements, the length of the vertical elements being a
multiple of U, at least some of the assembly elements further
comprising fluid pipes and/or electrical cabling.
[0036] Advantageously, at least some of the elements have male
connectors inserted at regular intervals on the rim of the
elements, and female connectors inserted symmetrically and facing
the male connectors on the corresponding rims.
[0037] Preferably, the rim of the assembly elements is machined at
each insertion point of a female connector to create a trench at
the bottom of which the female connector is housed.
[0038] Advantageously, the trench is wider on the edge of the rim
of the assembly element to facilitate the insertion of the male
connector.
[0039] According to a variant, the lower structural part of the
assembly elements is composed of a bracket reinforced by a metal
profile of rectangular cross-section defining a pipe for the
ventilation of the air.
[0040] Advantageously, orifices are drilled regularly along the
inner faces of the profile.
[0041] Preferably, the orifices also pass through the structuring
bracket.
[0042] The present disclosure also relates to a method of
constructing a prefabricated building according to the
aforementioned structure, characterized in that the following is
carried out successively: [0043] installing one or more horizontal
modules to form a floor, [0044] connecting a network of lower beams
on all the side faces of the horizontal module(s), [0045] elevating
the vertical walls by connecting a series of vertical modules and
posts on the upper face of the lower beams, and [0046] placing a
second network of horizontal beams to which horizontal panels will
ultimately be connected in order to compose the roof or the upper
level.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] The present disclosure will be better understood upon
reading the following description with reference to the
accompanying drawings, where:
[0048] FIG. 1 is an exploded perspective view of the construction
principle by connecting panels using corner beams;
[0049] FIG. 2 is a second exploded perspective view illustrating a
building constructed according to the construction principle;
[0050] FIG. 3 is a side cross-section showing the alignment of a
corner beam, a horizontal SIF panel (roof), and a vertical SIF
panel (wall);
[0051] FIG. 4 is a side cross-section illustrating a building whose
dimensions are multiples of the cross-section of the modules;
[0052] FIG. 5 is a perspective view of a male-type metal connector
and of a female-type metal connector for fixing the modules
together;
[0053] FIG. 6 is a perspective view of a beam incorporating a
series of invisible female-type metal connectors;
[0054] FIGS. 7a and 7b are side cross-sections of a beam configured
to integrate fluids;
[0055] FIG. 8 is a perspective view of a beam configured to
integrate fluids;
[0056] FIG. 9 is a cross-sectional view of a post configured to
integrate fluids;
[0057] FIG. 10 is a perspective view of a corner piece located at
the intersection of two upper beams;
[0058] FIG. 11 shows a first variant for the internal structure of
the vertical sandwich panel (SIF) of the wall type;
[0059] FIG. 12 shows an outer belt of a vertical sandwich-type
panel (wall);
[0060] FIG. 13 shows a perspective view of an SIF roof panel;
[0061] FIG. 14 shows a perspective view of a variant of the
assembly by means of machined connectors; and
[0062] FIG. 15 shows a perspective view of a vertical panel/beam
assembly by means of a twist-lock.
DETAILED DESCRIPTION
[0063] The general principle of the present disclosure involves
constructing a building by assembling prefabricated 2D modules on
the installation site, as shown in FIG. 1. The structure is thus
made up of horizontal (such as floors, roofs, glass roofs,
balconies) and vertical (such as walls, partitions, joinery)
elements assembled together by means of posts, beams and corner
pieces.
[0064] In order to raise the building, one or more horizontal
modules are first installed to form a floor (1). A network of lower
beams (2) is then connected to all the side faces of the horizontal
module(s). The vertical walls are then raised by connecting a
series of vertical modules (3) and posts on the upper face of the
lower beams. Then a second network of horizontal beams (4) is
placed to which horizontal panels (5) will ultimately be connected
in order to compose the roof or the upper level. FIG. 2 shows that
the walls and floors are composed at least in part of structural
panels and can also integrate non-structural elements (e.g.,
windows). When they are in contact with the outside, the panels can
be of the sandwich type and advantageously of the SIF type
(structural, insulated, finished). FIG. 3 shows, in cross-section,
a vertical SIF panel (6), a horizontal SIF panel (roof) (7) and a
corner beam (8). The material used for the structuring layer (9) of
the panels is of little importance for the understanding and
implementation of the present disclosure. Preferably, this layer
may consist of laminated wood, for example, CLT ("Cross-Laminated
Timber"), LVL or Lamibois (trade name). Those skilled in the art
could alternatively use other materials (concrete or composite
panels).
[0065] The insulating layer (10) consists of any type of insulation
(e.g.: wood wool, mineral wool, polystyrene). The interior finish
can be the structural material left raw, or a topcoat, for example,
plaster, paint, or PLACOPLATRE.RTM. (Trade name), not shown in the
figure.
[0066] The exterior finish is arbitrary (wood cladding, fiber
cement, sheet metal, plaster). The precise composition of each
sandwich panel is adapted according to its function (floor,
ceiling, roof, wall, interior partition) and the material chosen
for the structuring layer. For example, as can be seen in FIGS. 1,
2 and 3, the panels forming the roof comprise an outer face with a
slight slope to allow the evacuation of rainwater. However, it
should be remembered that, although having different compositions,
the sandwich panels are designed so that their total thickness is
substantially equivalent to the cross-section of the beam (denoted
U in FIG. 3).
[0067] In addition, this feature optionally makes it possible to
unify the dimensions of the different modules (FIG. 4). Indeed,
using a standardized dimensional system based on multiples of the
unit U (for example, U=40 cm) offers a considerable advantage to
those skilled in the art, insofar as modules can be produced in
series that are subsequently used in a wide variety of different
projects.
[0068] The panels and the beams can be fixed together using
techniques known to those skilled in the art (screws, dowels,
glues). However, to facilitate and accelerate the on-site assembly
of the building, a preferred assembly method involves using male
and female connectors.
[0069] FIG. 5 illustrates an example of a male (11)-female (12)
connector. The male connectors are inserted at regular intervals on
the rim of the various panels, while the female connectors are
inserted symmetrically and facing the male connectors on the
corresponding rims of the beams (FIG. 6). The connectors can be
aligned or staggered. To guide the male connector and make the
beam-panel connection invisible, the rim of the beam is machined at
each insertion point of a female connector to create a trench (13)
at the bottom of which the female connector (14) is housed.
Advantageously, the trench is substantially wider on the edge of
the rim of the beam to facilitate the insertion of the male
connector.
[0070] One of the problems that the present disclosure seeks to
solve being the management of fluids, the internal structure of the
posts and beams is used to circulate the electrical network, the
ventilation and the evacuation of rainwater. Thus, while playing a
structuring and insulating role, the posts and beams serve as a
technical box for arranging the passage of fluids. FIGS. 7a and 7b
illustrate one embodiment of the beams. The beams here are made up
of two parts. The lower structural part (15) is composed of a
bracket (16) (for example, glulam) reinforced by a metal profile
(17) of rectangular cross-section. The profile acts both as an
angle iron and as a duct for air ventilation. For this, orifices
are drilled regularly (ideally at an interval equal to the unit U)
along the internal faces of the profile. These orifices (21) also
pass through the structuring bracket, as can be seen in the
perspective view of the beam (FIG. 8). Along the profile, a raceway
(18) is fitted to pass the electrical network (high current, low
current, coaxial cables, Ethernet, fibers, etc.). The upper part of
the beam (19) incorporates the insulation and is terminated by a
channel (molded or extruded) allowing the evacuation of rainwater
that flows from the roof panels. A waterproof membrane (for
example, made from EPDM) covering the channel and overlapping the
adjacent roof panel by several centimeters ensures the
waterproofing of the whole.
[0071] The structure of the posts (FIG. 9) is comparable to that of
the beams. It also contains a structural part, an insulator (30), a
profile (31) for ventilation and a raceway (32) for carrying the
electrical network and a channel (33) for the water pipes. The
connection between the beams and the posts is made by means of a
corner piece (35) shown in FIG. 10.
VARIANT EMBODIMENTS
[0072] FIG. 11 shows a first variant for the internal structure of
the wall-type vertical sandwich panel (SIF) in the form of a
load-bearing panel made up of cross-laminated timbers (CLT)
providing the load-bearing function of the wall as well as its
bracing and its interior finish. The outer face (41) of the CLT is
covered (insulating side) possibly with a vapor barrier membrane.
Vertical posts (42) and/or horizontal joists (43) hold the
insulation (45) and secure the exterior cladding (44). The
rainscreen film (46) is disposed on the outer face of the
insulation. Cleats maintain an air gap (47) between the cladding
and the rainscreen film.
[0073] Alternatively, vertical posts are braced by a wood particle
board panel (e.g., OSB). The panel is lined with an internal
partition, for example, by means of plasterboard mounted on
aluminum profiles. A vapor barrier membrane is fixed to the inside
of the panel.
[0074] According to another embodiment, the inner face (41) is
composed of two wooden panels (for example, 3-ply or CLT) separated
by cleats providing an empty space for the passage of the
electrical ducts (52).
[0075] FIG. 12 shows an outer belt of a vertical-type sandwich
panel (wall). The belt (51) consists of composite wood boards
(e.g., LVL) coated on their outer face with a waterproofing
membrane (e.g., EPDM). Recesses are made in the belt for the
passage of the CMV (53) and electrical ducts (52).
[0076] Dovetail-type connectors (55) on the side rims (54) allow
the vertical modules to be fixed together, whether they are
wall-type SIF panels, corner posts, or modules incorporating
joinery. The other fixing techniques described herein can also be
applied.
[0077] Roof Element
[0078] FIG. 13 shows a perspective view of an SIF roofing panel
made of composite wood beams (CLT or LVL) (61), insulating material
(62) and two structural wood panels (CLT, or 3-ply) (63). For hot
areas, the particle board (OSB) (65) is insulated with one layer of
sound absorptive material (64) and covered with a waterproofing
membrane (e.g.: EPDM).
[0079] The floor panels have a similar structure. The dry mineral
floor consists of two boards of FERMACELL.RTM. (high-density
gypsum) (65) and a layer of sound-absorptive material (64).
[0080] A honeycomb structure filled with sand (62) is alternated
with composite wood beams (CLT or LVL).
[0081] Water and air tightness at the junction between two modules
(for example, a wall and a beam) is ensured by the EPDM coating.
The seal can be reinforced by means of a compressible sealing
gasket (COMPRIBAND.RTM.) placed under the EPDM of one of the
modules, combined with a recess on the module facing it.
[0082] Assembly by Machined Connectors
[0083] FIG. 14 shows a perspective view of a variant of the
assembly by means of machined connectors for the connection of the
horizontal modules to one another. Instead of the metal connectors,
a structural composite wood board (for example, lamibois) is used,
cut longitudinally to form two half-boards, denoted A and B.
[0084] The half-board (71) is fixed on the belt of a horizontal SIF
panel (floor or ceiling); the half-board (72) is in turn fixed
facing it on the beam. During assembly, the initial composite wood
board is reconstituted.
[0085] To hold the panel-beam assembly horizontally and thereby
replace the metal connectors, the board (71, 72) is cut in a
repeating pattern that functions as a series of tenon-mortise
connections. The pattern can be a series of slots or triangles,
sawtooths, dovetails, etc. An almost sinusoidal pattern is
particularly well suited because it facilitates the positioning and
the interlocking of the modules.
[0086] The lower half-board (71) can receive recesses for the
passage of ventilation and electricity ducts.
[0087] Connectors
[0088] FIG. 15 shows a perspective view of a vertical panel/beam
assembly by means of a twist-lock. Twist connectors are commonly
used in container transport. The connector known under the name of
"twist-lock" consists of a female part (81) fixed or machined
directly on the modules and a removable male connector (82) that is
inserted between two modules.
[0089] The pattern is repeated periodically. Here, the repetition
respects the U frame.
* * * * *