Patent Application
20190226198
The present invention relates to a framework module for use in modular building construction. More particularly, the present invention relates to a rigid box framework that forms a module for use in modular building construction.
Steel framing is a building technique that uses interconnected vertical and horizontal members to form a skeleton framework for a building. Once the framework has been constructed, the floors, roof and walls of the building are attached to and supported by the frame. This type of building technique is in common use. As well as vertical and horizontal members, a steel box frame typically requires diagonal bracing between the horizontal and vertical members in a number of key locations to provide structural stiffness. It can be difficult to use this type of construction method for modular construction, as the requirement for diagonal bracing can place significant limits on the number of different ways that the individual modules can be assembled.
In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common general knowledge in the art.
It is an object of the present invention to provide a framework module for use in modular building construction which goes some way to overcoming the abovementioned disadvantages or which at least provides the public or industry with a useful choice.
The term “comprising” as used in this specification and indicative independent claims means “consisting at least in part of”. When interpreting each statement in this specification and indicative independent claims that includes the term “comprising”, features other than that or those prefaced by the term may also be present. Related terms such as “comprise” and “comprises” are to be interpreted in the same manner.
As used herein the term “and/or” means “and” or “or”, or both.
As used herein “(s)” following a noun means the plural and/or singular forms of the noun.
Accordingly, in a first aspect the present invention may broadly be said to consist of a framework module for use in modular building construction, comprising: a plurality of elongate upright and cross beams, rigidly connected at or towards their ends to form a box frame with open side and end faces; at least one connection point on each of the upright beams, configured to allow mutual connection with an equivalent connection point located on a substantially identical adjacent framework module so that a plurality of framework modules can be connected together to form an open-web truss of vertically and horizontally aligned members.
Preferably the box frame and connection points are configured to have both vertical and horizontal axes of symmetry around the external planes of a box defined by a 2 meter by 2 meter by 3 meter volume within which the framework module is located.
Preferably the framework module for use in modular building construction further comprises at least one connection point on each of the cross beams.
Preferably the upright beams have a length of substantially 2.9 metres, and the cross beams have a length of substantially 1.7 metres.
Preferably each of the connection points is formed from a length of tube connected to an outwardly-facing portion of a beam.
Preferably the connection points are connected in parallel with the axis of the beam.
Preferably each of the upright and cross beams are formed from hollow tubes with a substantially square cross section.
Preferably the upright and cross beams are formed from 100 mm×100 mm SHS mild steel tube.
Preferably the connection points are located towards the inner side or edge of the beam.
Preferably each of the uprights and each of the cross beams further comprises a mutual connection means, configured to allow a plurality of cross beams to be connected to an upright substantially at the ends of the upright, perpendicular to the upright and to each other.
Preferably the mutual connection means comprises a plurality of upright brackets, connected to each of the uprights at or close to the ends, the brackets configured for connection to the cross beams.
Preferably the framework module for use in modular building construction further comprises a plurality of cross beam brackets connected to each of the cross beams at or close to the ends of the cross beams and configured to allow connection with the upright brackets.
Preferably the cross beam brackets are further configured to allow connection with adjacent cross beam brackets on an adjacent cross beam.
Preferably the upright brackets are configured to fit within and slide into an open end of the cross beams to allow connection.
Preferably each of the upright brackets comprises a right-angle bracket, at least one pair of brackets connected to the upright substantially at one end on adjacent faces of the upright, the upright brackets aligned in parallel with the axis of the upright.
Preferably the framework module for use in modular building construction further comprises a pair of brackets substantially at each end, on the same adjacent faces as the pair at the other end, all of the upright brackets aligned in parallel with the axis of the upright.
Preferably each of the cross beam brackets comprises a right-angle bracket, at least one pair of cross beam brackets connected to the upright substantially at opposite ends on one face of the cross beam, the cross beam brackets aligned perpendicular to the axis of the cross beam.
Preferably each of the upright brackets comprises a plurality of bolt holes passing through the face of the bracket aligned towards the other one of the pair at that end, and each one of the cross beam brackets comprises a plurality of bolt holes passing through the face of the bracket aligned towards the other one of the pair at the opposite end of the cross beam.
Preferably each one of the cross beam brackets further comprises a pair of notches at each end of the other face of the cross beam bracket.
Preferably each of the connection points has a length of substantially 200 mm.
Preferably each of the upright beams comprises a substantially centrally located connection point and an upper and a lower connection point spaced so that their mid-points are substantially 1000 mm from the mid-point of the centrally located connection point.
Preferably each of the cross beams comprises a pair of connection points each located with their mid-point substantially 500 mm from the centre of the cross beam.
Preferably each of the connection points is formed from a 40 mm×40 mm tube.
Preferably each of the connection points is formed from SHS mild steel.
In a second aspect, the invention may broadly be said to consist in a framework member for use in modular building construction, comprising: an elongate beam formed from a hollow tube with a substantially square or rectangular cross section; a mutual connection means at or towards at least one end and on at least one face of the beam, configured to allow connection of the elongate beam to a separate and similar elongate beam so that the beams extend perpendicular to one another once connected; at least one connection point on an outer surface of the beam partway along the axis of the beam.
Preferably the connection means comprises at least one bracket, connected to the beam at or close to the end and configured to fit within and slide into an open end of a separate similar beam to allow connection.
Preferably each of the upright brackets comprises a right-angle bracket.
Preferably at least one pair of brackets is connected to the beam substantially at one end on adjacent faces of the beam, the brackets aligned in parallel with the axis of the beam.
Preferably the framework member further comprises a pair of brackets substantially at each end of the beam, on the same adjacent faces as the pair at the other end, all of the brackets aligned in parallel with the axis of the beam.
Preferably each of the brackets comprises a plurality of bolt holes passing through the face of the bracket aligned towards the other one of the pair at that end.
Preferably the framework member has an overall length of substantially 2.9 metres.
Preferably a pair of brackets are connected to the same face of the elongate beam at opposed ends of the beam, the brackets aligned perpendicular to the axis of the beam.
Preferably each of the brackets comprises a plurality of bolt holes passing through the face of the bracket aligned towards the other one of the pair at the opposite end of the cross beam.
Preferably each one of the brackets further comprises a pair of notches at each end of the other face of bracket.
Preferably the beam has a length of substantially 1.7 metres.
Preferably each connection point is formed from a length of tube connected to an outwardly-facing portion of a beam
Preferably each connection point is connected in parallel with the axis of the beam.
Preferably each of the connection points has a length of substantially 200 mm.
Preferably each connection point is located towards an edge of the beam.
In a third aspect, the invention may broadly be said to consist in a building, comprising a plurality of framework modules as claimed in any one of the statements above.
In a fourth aspect, the invention may broadly be said to consist in a method of constructing a building using a plurality of framework modules as claimed in any one of the statements above, comprising the steps of:
With respect to the above description then, it is to be realised that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
Further aspects of the invention will become apparent from the following description which is given by way of example only and with reference to the accompanying drawings which show an embodiment of the device by way of example, and in which:
Embodiments of the invention, and variations thereof, will now be described in detail with reference to the figures.
A first embodiment of a framework module 1 is shown in
Connection points 4 are attached to or formed on the upright and cross beams 2, 3, on the outwardly-facing surfaces of the upright and cross beams 2, 3. The connection points 4 are not point elements, but are formed from 200 mm lengths of 40 mm×40 mm SHS mild steel tube. The connection points 4 are welded to the upright and cross beams 2, 3 with their long axis in parallel with the axis of the beam 2 or 3 to which they are connected. The connection points 4 are connected or attached so that they are aligned with the inside edge face of the beam to which they are attached. That is, so that the inner side face of the connection point 4 is directly adjacent to the edge of the open rectangle or square formed by the beams 2, 3, on any given side of the framework module 1.
When all the beams are inter-connected, and the connection points are fixed to the beams, the framework module 1 has a volume of nearly 2 m×2 m×3 m. In use, each framework module is treated as having a volume of 2 m×2 m×3 m. 10 mm spacers are used on each side of each of the connection points to make up the gap between interconnected framework modules 1. As shown in
The connection points 4 are formed so that they can be connected to connection points on an adjacently-located substantially identical framework module (either or both of above/below, and/or to the side), so that when a number of the framework modules 1 are connected together they form an open-web truss of vertically and horizontally aligned members.
The connection points 4 are connected to the beams 2, 3 as follows:
Three connection points 4a, 4b, 4c are attached to each of the upright beams 2, with a first connection point 4b substantially at the centre of the beam 2 (i.e. so that the mid-point of it's 200 mm length is at the mid-point of the beam 2—that is, 1.45 metres along the length of the beam 2), with the remaining two connection points 4a, 4c spaced so that their mid-points are one metre from the mid-point of the centrally located connection point 4b. That is, their inner ends are each 800 mm from the ends of the central connection point 4b, and their outer ends are each 350 mm from the ends of the beam 2.
Three further connection points 4d, 4e, 4f are attached on the other outwardly facing side of the upright beams 2 with the same spacing as 4a, 4b, 4c.
Two connection points 4i, 4j are attached to the side of each of the cross beams 3, in the same plane as the connection points 4a, 4b, 4c and spaced so that their mid-points are each 500 mm from the mid-point or mid-line of the cross beam 3. That is, the centres of the connection points 4i, 4j are one metre apart.
Two further connection points 4g, 4h are attached to the top of each of the upper cross beams 3 and bottom of lower cross beams 3 with the same spacing as the connection points 4i, 4j.
All connections points have a face adjacent to the inner edge of the outwardly facing sides of beam 2 and beam 3.
It can be seen that all the connection points along any one vertical or horizontal vector are spaced no more than 1 m apart (that is, the connection points on the cross-beams will be spaced 1 m apart from their closest neighbour on the same vector on a directly adjoining and connected framework module 1.
It can be seen that the framework module 1 and it's connection points 4 are configured to have both vertical and horizontal axes of symmetry through a 2 m×2 m×3 m box outside of the beams 2, 3.
In a second embodiment, and as shown in
In this embodiment, the beams 102 and uprights 103 are bolted together at their ends using integral brackets 105a, 105b and bolts, as described below. The brackets 105 are shown alone in
As shown in
As shown in
The brackets 105 have a length/height so that they will just slide into the open ends of the beams 103.
In use, as shown in
A metal reinforcing tab 113 is connected on the outer face of each vertical member via the single bolt hole 112. The tab 113 prevents the beam 103 from sliding out of alignment with the upright 102 due to the tension at 45 degrees and provides additional vertical load support for the upright 102.
As well as allowing the required rigid connection between members, this type of connection also allows adjustment of the connection between members, to ensure the connections are at the required angle—e.g. perpendicular. Members can be removed after assembly of multiple adjacent frames, stacked more effectively for transport, and assembled without the use of heavy machinery. The uprights 102 can be adjusted into perpendicular by adjusting the two nuts at the outer end of each of the four bolts connecting the upright 102 to the two beams 103. Similarly the two beams 103 can be adjusted through the bolted connections between their brackets 105b.
The bolting design enables uprights 102 to be removed by sliding away from the beams 103 at an angle of 135 degrees even after adjacent frames have been installed. This capability facilitates a unique build method where rooms are formed or changed after the structure has been put in place by adding and removal of uprights 102 within the frames 101. All connection bracket welding and bolting connections occur on the outside of the uprights 102. This preserves the vertical conduit. Leaving this space free of interference, allowing it to be used as a conduit for running utility cables and pipe work after the frames are in place and insertion of piles. Bolted connections allow pre-fabricated parts to be more efficiently transported to site and parts can be assembled without the use of heavy lifting equipment.
As shown in the figures for the second embodiment, the connection points 104 are substantially the same as those for the first embodiment, but have notched or slotted outer ends. It should be noted that notched or non-notched connection points could be used for either embodiment, although the notches or slots facilitate joining or connection via bolts or similar slipped into adjacent pairs of notches.
As noted above, in use a number of the framework modules 1 or 101 are connected together to form an open-web truss of vertically and horizontally aligned members, which is used to form a skeleton framework for a building. Rooms are configured by removing one or more uprights from the frame before or after construction and installation. The symmetry and geometry of the frame design of the framework module and connection points enable the use of a single exterior wall, floor and roof panels design that creates a continuous outer shell. The design of the framework module preserves vertical conduits (within the upright beams) within which utility pipe work and electrical cabling can be run and located. These vertical conduits are maintained continuously throughout the entire structure, through the upright beams in each framework module. Because the connection points are not at the corners, utility pipe work and cabling can be run through these vertical conduits and then distributed laterally within the floor and roof cavities between vertical stacked framework modules.
Using this construction method, structural stiffness is achieved when one framework module is connected to an adjacent framework module, which effectively makes a rectangular truss between any two connection points through the frame members. Connection points on the building outer sides can be used to mount exterior panels of single design for wall, roof and under floor. When a number of framework modules are mounted together, the connection points are always 1000 mm apart along the axis of either beam or beam.
It can be seen that mounting locations are consistent and symmetrical around the structure of the skeleton frame created by connecting a number of the framework modules 1 together. Therefore, exterior panels of a single design can be used for the building's outer floors, roof and walls. Regardless of which connection points are used, exterior panels mount in a manner which is symmetrical through the planes making up the 2 m×2 m×3 m volume. This allows panels to be mounted to any configuration of framework modules 1 and creates an outer building shell that can be sealed using typical builders silicon around any inward or outward framework module corner as well as any flat walls. Avoiding air leakage greatly improves any building's energy efficiency.
When used to create a skeleton structure for a building, the framework module is a repeating structure. This creates fabrication economies of scale. Furthermore, frames internal to the outer shell need not be painted or surface treated because moisture levels inside the shell can be controlled. A tower created by stacking framework modules vertically could be used for the remaining lifting and materials handling, which avoids the need for the use of a full time crane, which is required with most modular constructions. After completion of the required lifting, the tower can be incorporated into the building.
Building foundations can be created from the top part of a framework module. The uprights or upright beams are cut to lengths that will accommodate local topography. These foundation framework modules are supported on piles and their height can be adjusted using jacking screws after the pile has been set/grouted in place. Such a system allows piles to be statically loaded for testing and if further settling occurs, further adjustment can take place or at any time during the buildings use. If more adjustment is required than the existing pile length can accommodate, additional spliced pile length to further lift the foundation frame can be fed down through the upright beams which form vertical conduits.
When drilling piles, a foundation framework module 1 can be used to mount core drilling equipment which provides the required torsional stiffness (opposing core drill torque) and avoids the need for large/heavy drilling machinery. Because cores are drilled through the vertical conduits of the framework modules, pile location inaccuracies are avoided.
