Patent Application
20180355601
Conventional construction is mostly conducted in the field at the building job site. People in various trades (e.g., carpenters, electricians, and plumbers) measure, cut, and install material as though each unit were one-of-a-kind. Furthermore, activities performed by the trades are arranged in a linear sequence. The result is a time-consuming process that increases the risk of waste, installation imperfections, and cost overruns. One approach to improving efficiency in building construction may be modular construction. In the case of buildings with multiple dwelling units (e.g., apartments, hotels, student dorms, etc.), entire dwelling units (referred to as modules) may be built off-site in a factory and then trucked to the job site. The modules are then stacked and connected together, generally resulting in a low-rise construction (e.g., between one and six stories). Other modular construction techniques may involve the building of large components of the individual units off-site (e.g., in a factory) and assembling the large components in the field to reduce the overall construction effort at the job site and thereby reducing the overall time of erecting the building. However, shortcomings may exist with known modular building technologies and improvements thereof may be desirable.
Techniques are generally described that include systems and methods relating to building construction and more specifically relating to constructing and coupling a diaphragm to an external structural frame of a building. The diaphragm may be constructed at least in part from a plurality of pre-assembled floor and ceiling panels (also referred to as floor-ceiling panels).
A building system according to some embodiments of the present disclosure may include an external structural frame including a plurality of columns and beam, a diaphragm including a plurality of floor panels, each of the plurality of floor panels having a longitudinal direction and a transverse direction, and wherein the plurality of floor panels are supported by a plurality of diaphragm beams arranged along the transverse direction, and a coupling assembly between each of the transverse beams and the external structural frame such that structural loads are transmitted from the diaphragm to the external structural frame only via the coupling assemblies between the transverse beams and the external structural frame.
In some embodiments of the building system, each of the plurality of diaphragm beams may be fire-rated. In some embodiments, each of the plurality of diaphragm beams may be filled with a mineral-based material, such as concrete. In some embodiments, each concrete-filled beam may include at least one internal metal re-enforcing member (e.g., re-bar). In some embodiments of the building system, each of the plurality of floor-ceiling panels may be a pre-assembled panel comprising opposite longitudinal edges extending along the longitudinal direction, opposite lateral edges extending along the lateral direction, and a plurality of joist extending in the longitudinal direction in a spaced arrangement between the opposite longitudinal edges.
In some embodiments of the building system, a first one of the plurality of floor-ceiling panels may be pre-assembled to include a track extending along a first longitudinal edge of the first floor-ceiling panel, and the track may be configured to receive a floor-to-ceiling-window panel, and wherein the first floor-ceiling panel is unsupported by the external frame along the first longitudinal edge. In some embodiments, the track may be a first track attached to a floor side of the first floor-ceiling panel, and the first floor-ceiling panel may be pre-assembled to include a second track along the first longitudinal edge on a ceiling side of the first floor-ceiling panel, the second track being configured to receive another floor-to-ceiling window panel. In some embodiments, the first and second tracks are configured to slidably receive the respective floor-to-ceiling window panel.
In some embodiments, the first floor-ceiling panel may be pre-assembled to include a water impermeable member enclosing the first longitudinal edge. In some embodiments, the water impermeable member may be a plastic or a composite c-channel having an upper flange that extends fully under the first track and a lower flange that extends at least partially under the second track. In some embodiments, the upper flange may include a lip adjacent to an interior side of the first track and the lower flange may include a ledge adjacent to an exterior side of the second track. In some embodiments, the first floor-ceiling panel may include a second longitudinal edge configured to be coupled to a longitudinal edge of an adjacent floor-ceiling panel. As described, the first floor-ceiling panel may be unsupported by a beam of the external frame along the second longitudinal edge. In some embodiments, the plurality of floor-ceiling panels may include at least one middle floor-ceiling panel having first and second longitudinal edges connected to adjacent floor-ceiling panels, and the middle floor-ceiling panel may be unsupported by a beam of the external frame along both of the first and second longitudinal edges of the middle floor-ceiling panel. In some embodiments, the diaphragm may include a diaphragm edge opposite the first longitudinal edge of the first floor-ceiling panel, and a non-loadbearing wall may be coupled to the diaphragm along the diaphragm edge, for example a non-loadbearing wall that extends substantially the full length of the diaphragm edge.
In some embodiments, a first one of the plurality of diaphragm beams is coupled to a beam of the external structural frame and wherein a second one of the plurality of lateral beams is coupled to one of the plurality of columns of the external structural frame. In some embodiments, the first diaphragm beam may be a fire-rated beam which is parallel to a beam of the external structural frame. In some embodiments, the beams and/or columns of the external structural frame may not be fire-rated.
A method of assembling a building in accordance with some embodiments of the present disclosure may include erecting at least a portion of an external structural frame including a plurality of columns and a plurality of beams, wherein the plurality of beams includes at least a pair of first beams and a pair of second beams perpendicular to the pair of first beams, and assembling a diaphragm to the external structural frame. The assembling a diaphragm may include coupling each of a pair of diaphragm beams to the external structural frame, the diaphragm beams arranged parallel to the first beams of the external structural frame, and coupling a plurality of pre-assembled floor-ceiling panels to the pair of diaphragm beams such that each of the floor-ceiling panels is supported by the diaphragm beams along a transverse direction of the respective floor-ceiling panel and wherein each of the floor-ceiling panels is unsupported by any beam of the external structural frame along a longitudinal direction of the respective floor-ceiling panel.
In some embodiments, the coupling of each of the pair of diaphragm beams to the external structural frame may include coupling at least one of the pair of diaphragm beams directly to a pair of columns of the external structural frame. In some embodiments, the coupling of each of the pair of diaphragm beams to the external structural frame may include coupling one of the pair of diaphragm beams directly to the pair of second beams. In some embodiments, the coupling of the plurality of pre-assembled floor-ceiling panels to the pair of diaphragm beams may include coupling each floor-ceiling panel in the plurality in sequence. In some embodiments, the sequence may include coupling a first floor-ceiling panel including a window track to the pair of diaphragm beams, and coupling a second floor-ceiling panel to the pair of lateral beams and to the first floor-ceiling panel. In some embodiments, the sequence may further include coupling a third floor-ceiling panel to the pair of diaphragm beams and to the second floor-ceiling panel, the third floor-ceiling panel including at least one plumbing component. In some embodiments, the plurality of pre-assembled floor-ceiling panels is a first plurality of pre-assembled floor-ceiling panels, and the assembling a diaphragm may further include coupling an additional diaphragm beam to the external structural frame, and coupling a second plurality of pre-assembled floor-ceiling panels to one of the pair of diaphragm beams and the additional diaphragm beam. In further embodiments, each of the pair of diaphragm beams and the additional diaphragm beam may be coupled to the external structural frame prior to coupling any of the floor-ceiling panels of the first and second pluralities to the diaphragm beams.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are, therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings, in which:
all arranged in accordance with at least some examples of the present disclosure.
In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are implicitly contemplated herein.
This disclosure is drawn, inter alia, to methods, systems, products, devices, and/or apparatus generally related to pre-assembled panels for use in a building and to building systems which include a diaphragm provided by one or more pre-assembled panels. In some examples, the pre-assembled panel may be assembled off-site in a shop and then transported to the building site for assembly into the building system. At the building site, the pre-assembled panel may be attached directly or indirectly to a building frame. The building frame may be an external frame. The term external frame, also referred to as external structural frame, will be understood to refer to a structural frame of a building which is arranged generally externally to the envelope of the building. This is, in contrast to other types of structural frames that include vertical and horizontal load bearing members located within the perimeter defined by the building envelope, as is typical in timber construction for example, the external frame is arranged outside the perimeter of the building envelope. As is generally known in the field of structural engineering, the structural frame is the load-resisting or load-bearing system of a building which transfers loads (e.g., vertical and lateral loads) into the foundation of the building trough interconnected structural components (e.g., load bearing members, such as beams, columns, load-bearing walls, etc.). The design and construction of a building with an external frame may have advantages over internally framed buildings but may also bring new challenges, some of which may be addressed by examples of the present disclosure.
For example, building regulations in countries around the world impose requirements for the design and construction of buildings to ensure the safety to occupants of the building. In many countries, these regulations (also referred to as building codes), require that a building be designed and constructed such that, for example in case of a fire, the stability of the building (e.g., its load bearing capacity) is maintained for a reasonable period of time (e.g., a time sufficient to allow the occupants to egress the building). Therefore, typically, building codes in many countries impose fire proofing requirements to any load bearing structure (e.g., vertical and horizontal load bearing members). Modern steel framed buildings are sometimes constructed with external structural frames, i.e., where the structural frame on the outside of the facade, that is external to the building's envelope. In the event of a fire, an external structural frame may thus be heated only by flames emanating from windows or other openings in the building facade and the fire exposure to the external steelwork may thus be much less severe as compared to what the steel inside the building experiences. In some such cases, and depending on the design of the building and frame, the external frame, or at least some components thereof, may not need to be fire-proofed as is generally required any steel frame members located within the interior to the building. Thus using an external frame may in some cases significantly reduce construction costs by reducing the amount of fireproofing materials (e.g., spray on fire resistive materials and/or intumescent paint) required to meet code.
In some examples of the present disclosure, a building system may include a diaphragm attached to an external structural frame in a manner designed to reduce the amount of fireproofing material that may otherwise be required to meet code. The diaphragm of the building system may be provided by one or more, and typically a plurality, of pre-assembled floor panels. The use of pre-assembled floor panels may obviate the need for using concrete slab construction as is typically done, e.g., in mid- and high-rise construction. That is, in examples of the present disclosure, the diaphragm, which may provide a floor system of a building, may be constructed from pre-assembled floor panels without the use of a concrete slab, which may further improve the cost/efficiency of erecting the building by removing a step in a conventional building construction process (e.g., the concrete slab pouring/curing step). Additionally, the pre-assembled floor panels may be arranged in a manner that reduces the overall use of structural steel needed to support and transfer loads from the diaphragm to the external frame. Pre-assembled panels for use in a diaphragm according to the present disclosure may define part of or the whole of a floor and part of or the whole of a ceiling in the building, such as part of or the whole of a floor and ceiling of a building unit. Thus, in some examples, such pre-assembled panel may interchangeably be referred to herein as a floor and ceiling panel, a floor-ceiling panel, or a floor ceiling sandwich (FCS) panel. The floor may be a portion of a story of the building above the panel, and the ceiling may be a portion of a story of the building below the panel.
The pre-assembled panel(s) used in a diaphragm according to some embodiments may include a floor-panel frame, a floor panel, and a ceiling panel. The floor and ceiling panels may be spaced from one another by the floor-panel frame. The floor-panel frame may separate the floor panel from the ceiling panel. The floor-panel frame may include a plurality of joists positioned between the floor panel and the ceiling panel. The floor-panel frame may define one or more joist cavities between adjacent joists. In some examples, the one or more joist cavities may accommodate plumbing, cabling, wiring, or other conduits or other elements that may support dwelling or commercial units in the buildings. An insulative material may be located in the one or more joist cavities. In some examples, cross members may be provided in or operatively arranged relative to the one or more joist cavities, for example for increasing the lateral stability of the panel. In some examples, the cross members may be implemented in the form of straps, such as metal straps, connected between opposite corners of a joist cavity. Sound dampener material (also referred to as sound insulative material) may be positioned between the floor-panel frame, the floor panel, and the ceiling panel to reduce sound transmission through the floor and ceiling panel.
The floor panel may be attached to an upper side of the frame, also referred to as floor side of the frame. The floor panel may support a floor material (e.g., a floor finish such as tile, hardwood, manufactured wood, laminate or others) of an upper story. The floor panel may be formed of one or more layers of non-combustible material and may include a radiant heating element. The ceiling panel may be formed of one or more layers of non-combustible materials and may be attached to a lower side of the frame, also referred to as ceiling side of the frame. The ceiling panel may support a ceiling material (e.g., a ceiling finish such as ceiling tiles or other type of finish as may be desired) of a lower story. In some embodiments, the floor-ceiling panels may be implemented in accordance with any of the examples described in co-pending international patent application PCT/US17/21168, titled “Floor and Ceiling Panel for Slab-free Floor System of a Building,” which application is incorporated is incorporated herein by reference in its entirety for any purpose.
In some embodiments, the material composition of the floor-panel frame may be predominantly metal. In some embodiments it may be predominately aluminum. In still other embodiments, floor-ceiling panel components may be made from a variety of building suitable materials ranging from metals, to wood and wood polymer composites (WPC), wood based products (lignin), other organic building materials (bamboo) to organic polymers (plastics), to hybrid materials, or earthen materials such as ceramics. In some embodiments cement or other pourable or moldable building materials may also be used. In other embodiments, any combination of suitable building material may be combined by using one building material for some elements of the panel and other building materials for other elements of the panel. Selection of any material may be made from a reference of material options (such as those provided for in the International Building Code), or selected based on the knowledge of those of ordinary skill in the art when determining load bearing requirements for the structures to be built. Larger and/or taller structures may have greater physical strength requirements than smaller and/or shorter buildings. Adjustments in building materials to accommodate size of structure, load and environmental stresses can determine optimal economical choices of building materials used for all components in the system described herein. Availability of various building materials in different parts of the world may also affect selection of materials for building the panel described herein. Adoption of the International Building Code or similar code may also affect choice of materials.
Any reference herein to “metal” includes any construction grade metals or metal alloys as may be suitable for fabrication and/or construction of the system and components described herein. Any reference to “wood” includes wood, wood laminated products, wood pressed products, wood polymer composites (WPCs), bamboo or bamboo related products, lignin products and any plant derived product, whether chemically treated, refined, processed or simply harvested from a plant. Any reference herein to “concrete” includes any construction grade curable composite that includes cement, water, and a granular aggregate. Granular aggregates may include sand, gravel, polymers, ash and/or other minerals.
In referring now to the drawings, repeating units of the same kind or generally fungible kind, are designated by the part number and a letter (e.g. 214n), where the letters “a”, “b” and so on refer to a discrete number of the repeating items. General reference to the part number followed by the letter “n” indicates there is no predetermined or established limit to the number of items intended. The parts are listed as “a-n” referring to starting at “a” and ending at any desired number “n”.
The building 101 may include two or more stories or levels 103. The envelope of the building 101 may be defined by exterior walls and windows, e.g., by end walls 108, window panels 104, which may include floor to ceiling window panels defining a window wall, and/or utility walls (not shown in this view). These walls may be referred to as the building's exterior or envelope walls. The interior of the building 101 may be divided into one or more dwelling or commercial units 105 and/or one or more rooms of a unit using interior walls, also referred to as demising walls 106. In embodiments of the present disclosure, the various walls (e.g., demising walls 106, end walls 108, and window walls) of the building 101 may not be load bearing walls. Rather, structural loads may be transferred to and carried by the external structural frame 110. Structural loads (e.g., lateral loads from wind and/or earthquakes) may be transferred to the external structural frame 110 via the diaphragm 120, as will be further described.
The building 101 may be classified as a low-rise, mid-rise, or high-rise construction depending on the number of stories (each city or zoning authority may define building heights in any fashion they deem proper). The building 101 may include, as part of the diaphragm 120, one or more floor-ceiling panels 122. A floor-ceiling panel as described herein may be suitable for use in a building of any number of stories (levels), including a mid-rise building and a high-rise building. In some embodiments, the building may be a residential multi-dwelling building having six, seven, eight or more stories, and in some example twenty five, thirty five, fourth five, or more stories (e.g., as in high-rise or skyscraper construction).
As shown and described, the building 101 may include an external structural frame 110. The external frame 110 may serve as a structural exoskeleton of the building 101. The external frame 110 may include multiple columns 112 (also referred to as frame columns), beams 114 (also referred to as frame beams), and/or cross braces 116. The columns 112 are oriented vertically, the beams 114 are oriented horizontally, and the cross braces 116 may be oriented horizontally or obliquely to the columns 112. For example cross braces may be horizontally oriented (e.g., as the frame beams 114) connecting adjacent columns, or they may be obliquely oriented to the columns and/or beams, e.g., as the cross-braces 116 illustrated in the example in
The building 101 may include multiple units or modules 105 disposed internally of the external frame 110. The units 105 may be commercial, residential (such as dwelling units), or a combination thereof (e.g., live-work units). The units may be standardized and repetitive, or unique and individualized. Mixed units of standard size and shape may be combined with unique units in the same floor, or in independent arrangement on separate floors. In some embodiments, a unit may encompass more than one floor. The units 105 may be assembled at the building site using multiple pre-assembled or pre-assembled components (e.g., pre-assembled floor-ceiling panels 122, prefabricated walls, etc.). The pre-assembled components may be assembled independent of one another remotely from the building site and transported to the building site for installation. The pre-assembled components may include, as delivered to the building site, most or all of the components to support the commercial or residential use of the units, e.g., electrical and/or plumbing conduits, heating and air conditioning ducting, etc. Thus, installation of sub-systems in the field may be reduced, thus again reducing the overall cost and construction timeline. The pre-assembled components may be attached to the external frame 110, to adjacent components, or both at the building site to erect the building 101 and form the individual units 105. In some embodiments, the building 101 may include internal support (e.g., load-bearing) structures. For example, the diaphragm 120 may include one or more support beams (see e.g., transverse beams 230 in
Pre-assembled components according to the present disclosure may include one or more pre-assembled or pre-assembled floor-ceiling panels 122 and one or more pre-assembled or pre-assembled walls (e.g., demising wall 106, end wall 108). The floor-ceiling panels 122 are oriented substantially horizontally to define the floor of an upper unit and the ceiling of a lower unit. Individual floor-ceiling panels 122 may be arranged horizontally and adjacent to one another along their longitudinal direction. The longitudinal direction may be the direction of longer length of a rectangular panel. The longitudinal direction may be the direction along which the joists run. The transverse direction may be direction of shorter length of a rectangular panel, i.e., the direction perpendicular to the longitudinal direction. The longitudinal and transverse directions refer to the planform shape of the panel, each panel also having a thickness direction which is perpendicular to the longitudinal and transverse directions. In some examples, the panels may be generally square in shape in which case the longitudinal direction may be the direction along which the joists run. Individual floor-ceiling panels 122 may be attached to one another, one or more columns, one or more beams, or any combination thereof. The individual floor-ceiling panels 122 may be coupled to and supported by diaphragm beams, which in turn may be coupled to the external frame, such as via a coupling assembly between a respective diaphragm beam and one or more beams 112 and/or columns 114 of the external frame 110 to transfer loads from the diaphragm 120 to the external frame 110. The walls (e.g., demising walls 106 and end walls 108) may be oriented substantially vertically to define the envelope of the building and/or partition each story into multiple units, a single unit into multiple rooms, or combinations thereof. The walls may be attached to the floor-ceiling panels 112 with fasteners and then caulked, sealed, or both. In some embodiments, some of the walls of building 101 may additionally or alternatively be attached to the diaphragm beams that support the floor-ceiling panels 112.
The floor system 202 may be part of a multi-story building (e.g., building 101 in
In the case of an external frame, the columns 212 (e.g., columns 212-1, 212-2, 212-3, and 212-4) may be arranged around the perimeter of the building. The beams 114 may connect adjacent columns and the columns and beams 212, 214, respectively, of the structural frame 210 may define, when viewed in plan as shown in
In the illustrated example in
Referring now further to
The panels 222 may be supported by diaphragm beams 230 along their transverse edges. In some embodiments, the panels 222 may be supported only along their transverse edges. In some examples, each panel may include one or more second mounting components (e.g., one or more angle or L-shaped brackets) which may be rested against and joined (e.g., mechanically fastened, welded or otherwise joined) to a diaphragm beam 230. For example, the lateral edges 262-1 of the panels 222 may be joined to diaphragm beam 230-1 and the opposite lateral edges 262-2 of the panels 222 may be joined to another diaphragm beam 230-2. The diaphragm beam 230-1 may be arranged near and extend between end columns 212-1a and 212-1b. The diaphragm beam 230-2 may be arranged to extend between columns 212-2a and 212-2b. The diaphragm beams 230 may be joined to the external frame and may thereby transfer load from the diaphragm to the frame. For example, opposite ends of the diaphragm beam 230-1 may be joined to each of the pair of frame beams 212-2a and 214-22b. In other embodiments, the diaphragm beam 230-1 may be joined to directly to the columns or another component of the external frame. In some embodiments, the diaphragm beam 230-1 may be adjacent to (e.g., parallel to) a frame beam 214-1a that connects the end columns 212-1a and 212-1b. While the diaphragm beam 230-1 may be fire-rated, the frame beam 214-1a may or may not be fire-rated. The term fire-rated in the context herein is generally used to imply that the component is configured to meet the relevant fire code. In some examples, both of the adjacent beams (e.g., the diaphragm beam 230-1 and the frame beam 214-1) may be configured such that they meet the fire code. In some embodiments, the diaphragm beams (e.g., beams 230-1, 230-2) may be filled with a mineral based material such as concrete (for example, see beam 230-2 in
The diaphragm may not be joined to a load bearing member along its longitudinal edges 221-1 and 221-2. Rather all loads from the diaphragm may be transferred to the external frame via the diaphragm beams 230, e.g., via the coupling assemblies 240 between the diaphragm beams 230 and the external frame 210, for example by following the load path diagrammatically illustrated by arrows A-C. As shown, load may be transferred along the diaphragm towards the transverse edges 262-1, 262-2 of the panels 222 as shown by arrows A. The load may be transferred to the diaphragm beams 230 (e.g., by the joints between the floor-ceiling panels and the diaphragm beams) and may then be transmitted along the diaphragm beams 230 toward the external frame 210 as shown by arrows B. The load may be transmitted from the diaphragm 220 to the external frame 210 via the coupling assemblies 240 between the diaphragm beams 230 and the external frame 210. For example, load may be transmitted to the beams (e.g., beams 214-2a and 214-2b) and then the columns (e.g., columns 212-1a and 212-1b), as shown by arrows C, or directly to a column (e.g., columns 212-2a, 212-2b) of the external frame 210, which then transfer the load to the foundation.
As illustrated, the panels 222 that form part of the diaphragm are not directly joined to the structural frame along at least one longitudinal edge (also referred to as unsupported longitudinal edge) and thus no load is transferred to the structural frame trough the interface of any other building components arranged along the unsupported longitudinal edge. Rather structural loads are transmitted from the panels to the diaphragm beams (e.g., via the internal structure of each panel such as the joists) and then the load is transmitted to the external frame via the coupling assemblies 240. In this regard, the panels 222 may be said to be unsupported along at least one of their longitudinal edges. In some embodiments, non-loadbearing walls may be joined to the floor-ceiling planes 222 along the longitudinal unsupported edges, such as a window wall or a utility wall. In some embodiments, one or more of the non-load bearing walls (e.g., end wall 108, window walls, utility walls) may be continuous walls that span the full distance between two columns of the external frame. For example, in the illustrated embodiment in
The individual layers of the floor panel 226 and the ceiling panel 228 may be formed using discrete (e.g., separable) pre-manufactured construction elements (e.g., boards of non-combustible materials, such as cement board, magnesium oxide (MgO) board, fiber-cement board, gypsum board, fiberglass-clad cement or gypsum board, metal-clad cement or MgO board, and other suitable mineral-based materials), which may be joined to the floor-panel frame 224 off-site (e.g., in a factory or other location remote) prior to delivery of the floor-ceiling panels 222 to the building site, thus reducing on-site construction time/costs. The floor panel 226 may include at least one layer 225 made substantially from non-combustible material (e.g., cement board, magnesium oxide (MgO) board, etc.) and at least one metal diaphragm layer (e.g., a sheet of steel such as a 22 gage steel sheet or another). The metal diaphragm layer 229 may be attached to (e.g., bonded or mechanically fastened) the non-combustible material and/or to the floor-panel frame 224. In some embodiments, the metal diaphragm layer may be simply sandwiched between layers of the floor panel 226 and/or the floor-panel frame 224 (e.g., between a layer of non-combustible material and the frame or between two layers of non-combustible material) without being otherwise attached thereto. In some embodiments, the floor panel 226 may include a radiant heating element 219, which may be provided in a layer (e.g., foam or other type of insulative layer 227) of the floor panel 226. The ceiling panel 228 may include at least one layer (e.g., layers 228-1, 228-2) made substantially from non-combustible material (e.g., cement board, magnesium oxide (MgO) board, fiber-cement board, gypsum board, fiberglass-clad cement or gypsum board, metal-clad cement or MgO board, and other suitable mineral-based materials).
In some embodiments, the panel frame 224 (e.g., joists 215) may be formed of metal, such as aluminum or steel. In some embodiments, the panel frame 224 may be formed of a non-metallic material, such as wood, plastic, or composite materials such as fiber reinforced composites. In the illustrated example, the joists 215 are implemented using metal C-channels, e.g., of lightweight steel as manufactured by Steelform Building Products Inc. (marketed under the name Mega Joist). A variety of other types of joists, for example and without limitation I-shaped, or closed, box shaped joists may be used in other embodiments. The insulation 217 provided in the panel 222 may include thermal and/or sound insulation. For example, sound dampening materials (e.g., sound strips) may be provided between the individual layers of the floor panel 226 and the ceiling panel 228 and/or between these panels and the frame (e.g., between the panels and the joist).
The floor-ceiling panels 222 may define a generally enclosed space by the floor-panel frame 224 and the floor and ceiling panels 226, 228, respectively. Mounting components (e.g., angles, angle clips, L-shaped or C-shaped brackets, or brackets of other types or geometries) may be joined to the floor-panel frame 224 along the longitudinal and transverse edges of the panel 222 for joining each panel to an adjacent panel and/or to a diaphragm beam.
In some embodiments, at least one floor-ceiling panel of the plurality of floor-ceiling panels that form the diaphragm may be pre-assembled to include a track configured to receive one or more window panels. For example,
The portion of panel 400 shown in
The panel 400 may include a first track 420-1 extending along a longitudinal edge 410 of the panel 400. The track 420-1 may be configured to receive at least one floor-to-ceiling-window panel 430. The first track 420-1 may be attached to the floor side 401 of the first floor-ceiling panel 400. The panel 400 may include a second track 420-2 attached to the ceiling side 403 of the floor-ceiling panel 400 and extending along the longitudinal edge 410 of the panel 400. The second track 420-2 may be similarly configured to receive at least one floor-to-ceiling-window panel 430. As will be understood, the first track 420-1 may receive the lower proton(s) of at least one floor-to-ceiling-window panel (e.g., bottom portions of floor-to-ceiling-window panels 430-a, 430-b, and 430-c), while the second track 420-2 may receive the upper proton(s) of at least one floor-to-ceiling-window panel (e.g., upper portions of floor-to-ceiling-window panels 430-d, 430-e, and 430-f). The floor-to-ceiling-window panel(s) may thus define a window wall of a unit, such as unit 105 of the building 101 in
In some embodiments, at least one floor-ceiling panel of the plurality of floor-ceiling panels that form the diaphragm may be pre-assembled to include a water impermeable member enclosing a longitudinal edge of the panel. For example, as shown in
The water impermeable member 440 may include an upper flange 442, a lower flange 444, and a web 445 connecting the upper and lower flanges 442 and 444, respectively. The upper flange 442 may extend fully under the first track 420-1, which may reduce or minimize the risk of water intrusion and thus facilitate sealing the building envelope (e.g., once the window panels are installed). In some embodiments, the upper flange 442 may include a lip 448 protruding from the flange 442. The lip 448 may adjacent to, in some cases abutting, an interior side of the track 420-1, which may provide a more robust and water-resistant assembly.
The lower flange 444 may extend at least partially, or in some cases fully, under the second track 420-2, which may again serve to reduce or minimize the risk of water intrusion. The lower flange 444 may include a ledge 446 which may be adjacent to an outer side of the track 420-2. The ledge 446 may protrude downward from the flange 444. By providing a ledge 446 on the exterior side of the track 420-2, the gap between the track 420-2 and the ceiling side 403 of panel 400 may be better sealed against water intrusion. In some embodiments, the lower flange 444 may additionally or alternatively include a lip protruding downward and arranged on the interior side of track 420 similar to the arrangement on the floor side. In some embodiments, the water impermeable member 440 may be a single continuous member wrapping around the longitudinal edge 410 of the panel 400, that is covering at least a portion of the floor side 401, a portion of the ceiling side 403 and the edge side of the longitudinal edge 410 of the panel 400. In other embodiment, for example as shown in
Referring back to
Specifically,
Each of the frame beams 241-2a and 241-2b may be implemented using an I-beam for example (see also
The leg portion 242-1 may be implemented using a metal plate (e.g., structural steel or other) and may have a height selected to fit between the flanges 510-1 and 510-2 of the I-beam. In some embodiments, the leg portion may have one or more base flanges, for example to allow the leg portion to be bolted to the web 512. In other embodiments, the leg portion may not include base flanges, such as when welding the connector bracket to the web 512. The connector bracket 241-1 may additionally or alternatively be coupled (e.g., welded) to the flanged 510-1 and 510-2. The top or flange portion 244-1 of the connector bracket 241-1 may be implemented also using a metal plate (e.g., structural steel or other) and its length (in the vertical direction, when installed) may be greater, in some embodiments, than the distance between the flanges 510-1 and 510-2 of the I-beam. The flange portion 244-1 may be configured to be substantially coextensive with the end cap 231 of the diaphragm beam 230-1, which may enable better load transfer from the diaphragm to the frame. The base or leg portion 242-1 may but need not be centered on the top portion 244-1. In some cases, it may be advantageous for the top portion 244-1 to be off center depending on the desired vertical location of the diaphragm beam 230 in relation to the frame beam 214-2a. Also, typically, the brackets 241-1, 241-2 may be formed as integral, monolithic parts (e.g., the leg portion 242-1 and flange portion 244-1 are integrally formed by casting, machining, or other suitable technique); however, it is envisioned that the two parts may alternatively be separately formed and rigidly joined (e.g., welded).
The window wall 502 may extend along the longitudinal unsupported edge of the diaphragm 220-1. In some examples, a plurality of separable floor-to-ceiling window panels 504 may be used to define a full window wall, e.g., a wall that spans the full length of the longitudinal edge of the diaphragm 220-1. In some cases, the individual floor-to-ceiling window panels 504 may be coupled to the diaphragm such that they are slidable along the longitudinal edge thereof. As described, the floor-ceiling panels may be delivered to the building site with a window track already pre-installed. Similarly, walls adjacent to the floor-ceiling panel that includes a window track may similarly be delivered to the building site with a wall-side track pre-installed thereon, such that field installation of the window wall mostly involves the coupling of the individual window panels 504 to the respective tracks. This may further enhance efficiency as the steps of glazing or caulking that are typically part of conventional construction (e.g., in steel-glass buildings) are substantially obviated.
The assembly shown in
In some embodiments, the demising wall 506 may be pre-assembled and delivered to the building site with the interior wall finish 609 material, some of which may be temporarily removed at the site, e.g., to facilitate installation of demising wall 506. In some embodiments, the demising wall 506 may be positioned directly over the diaphragm beam 230-2 and in some examples, may be fastened to the beam 230-2 and or the respective floor-ceiling panels. However, as described, the demising wall 506 may be coupled to the diaphragm 220 (e.g., diaphragm beam 230-2 and/or floor-ceiling panels) in a manner so as not to transmit or carry structural loads. That is, the coupling between the demising wall 506 and the diaphragm 220 may be generally for positioning and retaining be demising wall 506 in place rather than for providing a load path for structural loads (vertical and/or lateral loads experienced by the building). In some examples, the demising wall may be coupled to the diaphragm beam 230-2 and/or floor-ceiling panels using a non-rigid connection (e.g., using springs or movable components). Such non-rigid connection may allow the beam 230-2 and/or floor-ceiling panels to displace slightly relative to the wall 506, such as when carrying diaphragm loads, which may avoid any significant transference of loads to the non-load bearing wall 506. In some embodiments, the demising wall 506 may be implemented in accordance with any of the examples described in co-pending international patent application PCT/US17/21174, titled “Prefabricated Demising Wall with External Conduit Engagement Features,” which application is incorporated herein by reference in its entirety for any purpose.
As further illustrated in
Any of the diaphragm beams described herein may be implemented using a steel, closed-cross section member 702, e.g., a beam with a hollow structural section (HSS), which in some embodiments may be filled with a mineral-based material 705 (e.g., concrete) or other type of fire-resistant material. Filling the interior of the diaphragm beams with a mineral-based or other type of fire-resistant material may enable the beams to be fire-rated, e.g., to meet fire code, and thus obviate the need to use other types of fire resistant treatments (e.g., intumescent paint, spray on insulation, etc.), which may be more costly or more time consuming to install.
In some embodiments, the diaphragm beams, or a portion thereof may be additionally optionally thermally insulated, particularly at the envelope (e.g., at the joint with a highly thermally conductive metal column). In some embodiments, the coupling assembly associated with each diaphragm beam (e.g., coupling assemblies 240-3 and 240-4) may include a thermal break material 706, disposed between the diaphragm beam and the column (e.g., between end caps 704 of diaphragm beam 230-1 and the respective webs 610 or the respective columns 212-2a and 212-2b). The thermal break material may be a plastic or composite material or any suitable material having a lower thermal conductivity than the metallic materials used for the columns and beams (e.g., structural steel). In some embodiments, at least the end portions of the diaphragm beams (e.g., any exposed portion of the diaphragm beams) may be additionally or optionally enclosed by a thermally insulate material 720 (e.g., plastic, fiber-reinforced plastic (FRP), other composite material or a mineral-based with relatively lower thermal conductivity than the beams and columns). In some embodiments, the thermally insulate material 720 may be spaced from the sides of the steel member 702 to accommodate additional insulation 710 (e.g., semi rigid mineral wool). The additional insulation may be provided along the full length of the steel member 702, such as between the beam and adjoining floor-ceiling panels, regardless of whether or not the insulation 710 extends along the full length of the member 702. As further shown in
An example method 800 may include erecting at least a portion of an external structural frame, as shown in block 810. The external structural frame (e.g., frame 210) may include a plurality of columns and a plurality of beams. Thus, the erecting at least a portion of the external structural frame may include the erecting of a plurality of vertical columns, and coupling a plurality of horizontal beams to the columns. The plurality of beams, also referred to as frame beams, may include at least a pair of first beams and a pair of second beams perpendicular to the pair of first beams.
The method may continue by assembling a diaphragm to the external structural frame, as shown in block 812. For example this may involve coupling each of a pair of diaphragm beams (e.g., beams 230-1 and 230-2) to the external structural frame (e.g., frame 210). The diaphragm beams may be coupled using coupling assemblies or joints (e.g., coupling assemblies 240-1, 240-2, 240-3, and 240-4). Each of the diaphragm beam may be joined at its opposite ends to a frame beam and/or directly to a column of the structural frame 210. The diaphragm beams may be joined to a respective load bearing member by mechanical fasteners (e.g., bolts), welding, or other suitable techniques. The assembling of the diaphragm may further involve coupling one or more pre-assembled floor-ceiling panels (e.g., floor-ceiling panels 222) to the diaphragm beams. Each floor-ceiling panel may be arranged with its opposite transverse edges resting onto a respective one of the pair of diaphragm beams. To that end, each floor-ceiling panel may be equipped with at least one mounting component (e.g., angles, angle clips, L-shaped brackets, or other suitable brackets) for connecting each floor-ceiling panel to the respective diaphragm beam. In some embodiments, the diaphragm beam may be a rectangular hollow structural section beam. The mounting components may be L-shaped brackets attached to a transverse edge of a floor-ceiling panel with one leg of the L-shaped bracket rigidly secured to the narrow (e.g., thickness) or another side of the floor-ceiling panel and the other leg of the L-shaped bracket projecting perpendicularly therefrom. The projecting legs at the opposite transverse edges of the floor-ceiling panel may be rested onto a top surface of the respective diagram beam and the floor-ceiling panel may then be secured to the diaphragm beams by mechanically joining (e.g., fastening or welding) the brackets to the diaphragm beams.
If multiple floor-ceiling panels are used to form a diaphragm, adjacent panels may be joined to the diaphragm beams and to one another. In some examples, the coupling of a plurality of floor-ceiling panels may involve coupling each floor-ceiling panel in the plurality in sequence (e.g., attach a first floor-ceiling panel to the diaphragm beams, attach a second adjacent floor-ceiling panel to the diaphragm beams and the previous panel, attach a third floor-ceiling panel to the diaphragm and the middle panel, etc.). Regardless of the number of diaphragm portions in a diaphragm according to the present disclosure, the diaphragm may be coupled to the external structural frame in a manner which provides a load path (i.e., for transmitting loads from the diaphragm to the frame) only via the coupling assemblies between the diaphragm beams and the frame. In the case of multiple floor-ceiling panels forming the diaphragm, adjacent floor-ceiling panels may be joined to one another and the outer most two floor-ceiling panels may have one respective unsupported longitudinal edge, corresponding to the free or unsupported edge of the diaphragm.
In some embodiments, e.g., as shown in blocks 816 and 818, the building envelope may be defined by installing walls (e.g., end walls, utility walls, and or window walls), and the interior of the building may be divided into units or rooms by installing interior walls (e.g., demising walls). As described herein, these walls may be provided by one or more pre-fabricated walls which are positioned, for example, over the diaphragm beams and connected thereto and/or to the floor-ceiling panels below and above the walls. As further described, some or all of these pre-assembled walls may be non-load bearing walls and may be coupled to the diaphragm in a manner which avoids the transference of structural loads to the walls.
In some embodiments, at least one of the plurality of panels may include a track for receiving a floor-to-ceiling window panel. After floor panels associated with an upper story have been similarly assembled, one or more floor-to-ceiling window panels may be inserted into the tracks (e.g., snapped into engagement with a lower and upper track) to seal the envelope of the building. To facilitate installation of the window panels, the tracks and/or window panels may be provided with a biasing member to allow the window panel to slip into engagement with the track. Since the tracks are pre-installed onto the respective floor-ceiling panels and pre-assembled walls, a time consuming step of glazing and caulking of windows as is typically done in conventional construction, may be avoided, thus reducing the overall building construction timeline and costs.
In some embodiments, the diaphragm may include multiple diaphragm portions (e.g., 220-1, 220-2, etc.) to provide a building with as large a foot print as may be desired. In such embodiments, additional portions of the diaphragm may be assembled, for example by coupling at least one additional diaphragm beam to the external structural frame and coupling one or more additional pre-assembled floor-ceiling panels to the additional diaphragm beam, e.g., as shown in block 814. The additional diaphragm beam would be located at the same vertical elevation or height as the first pair of diaphragm beams and would be spaced horizontally therefrom to accommodate the additional one or more floor-ceiling panels. This sequence may be continued to assemble as large a floor system as may be desired, for example a floor system including four diaphragm portions as shown in
In some embodiments, coupling a diaphragm beam to the external structural frame may include coupling at least one of the pair of lateral beams directly to a pair of columns of the external structural frame. In some embodiments, coupling a diaphragm beam to the external structural frame may include coupling at least one of the pair of lateral beams to load bearing members other than columns, e.g., to a pair of frame beams such as beams 214-2a and 214-2b of
The present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as illustrations of various aspects. Many modifications and embodiments can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and apparatuses within the scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and embodiments are intended to fall within the scope of the appended claims. The present disclosure includes the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this disclosure is not limited to particular methods, reagents, compounds compositions or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.).
It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, means at least two recitations, or two or more recitations).
Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.
As will be understood by one skilled in the art, for any and all purposes, such as in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as “up to,” “at least,” “greater than,” “less than,” and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member. Thus, for example, a group having 1-3 items refers to groups having 1, 2, or 3 items. Similarly, a group having 1-5 items refers to groups having 1, 2, 3, 4, or 5 items, and so forth.
While the foregoing detailed description has set forth various embodiments of the devices and/or processes via the use of block diagrams, flowcharts, and/or embodiments, such block diagrams, flowcharts, and/or embodiments contain one or more functions and/or operations, it will be understood by those within the art that each function and/or operation within such block diagrams, flowcharts, or embodiments can be implemented, individually and/or collectively, by a wide range of hardware, software, firmware, or virtually any combination thereof.
The herein described subject matter sometimes illustrates different components contained within, or connected with, different other components. It is to be understood that such depicted architectures are merely examples, and that in fact many other architectures can be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively “associated” such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as “associated with” each other such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being “operably connected”, or “operably coupled”, to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being “operably couplable”, to each other to achieve the desired functionality. Specific embodiments of operably couplable include but are not limited to physically mateable and/or physically interacting components and/or wirelessly interactable and/or wirelessly interacting components and/or logically interacting and/or logically interactable components.
While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
| Number | Date | Country | |
|---|---|---|---|
| 62505692 | May 2017 | US |
