The field of the invention relates to architectures based on wooden structures. The invention relates more particularly to an improvement to the construction elements used for houses with wooden structures.
Houses with wooden structures, also called MOBs, offer many advantages such as a gain in construction time, a gain in insulation with respect to the space occupied and houses with wooden structures are also cheap and environmentally friendly. The construction of houses with wooden structures is based on different techniques which permit rapid assembly carried out for example by two people. However, the assembly remains relatively complicated and is generally carried out by professional tradesmen specialised in this field. Furthermore, even if the wood used for the construction is an ecological material, the manufacture of certain pre-fabricated elements in rough wood generates losses of raw material associated to high energy consumption, when the rough wood is machined. The pre-fabricated elements made of wood are for example beams, joists and cleats.
The purpose of this invention is to propose pre-fabricated elements, for example for the construction of houses with wooden structures, of which the manufacture permits raw materials and energy to be saved.
Another purpose is that the manufacture of all of the component pre-fabricated elements, for example of a house, is quicker than according to know manufacturing modes.
Another purpose is that the assembly of the pre-fabricated elements is simpler and quicker, compared to the assembly of the elements currently used.
These purposes are achieved by means of a pre-fabricated construction element for wooden architectures which comprise at least one portion forming a panel and at least one element forming a panel support that is attached to the panel, made from a single piece of pressed wood by a moulding or extrusion type manufacturing method, characterised in that a plurality of support elements form stiffeners which compose lateral cleats each joined to a lower rail and to an upper rail, wherein the pre-fabricated element which composes a wall is sealed at least partially by the panel, the pre-fabricated element rests on its lower rail, and the upper rail, supported by the lateral cleats, is positioned at a height which corresponds to the height of the ceiling.
According to another specific aspect, at least one protruding quick attachment hook is positioned on the external edge of one of the two lateral cleats and at least one slot to accommodate the quick attachment hook is located on the outside edge of the other lateral cleat.
According to another specific aspect, the outside edge of one of the two lateral cleats comprises a first surface that is “S” shaped to block the air, that is curved or is in the form of a broken line and the external edge of the other lateral cleat comprises a second surface that is “S” shaped to block the air, that is curved or is in the form of a broken line that is complementary to the first one, to form an assembly between the two surfaces.
According to another specific aspect, the sealing panel has an undulated or broken line profile.
According to another specific aspect, the panel comprises at least one stiffener positioned on an external face of the panel and which forms a support surface for an insulating wall panel.
According to another specific aspect, the pre-fabricated element comprises in the panel a stiffener which forms a window frame positioned around the window opening, wherein the frame comprises an upper rail and a lower rail that are attached to two lateral posts.
According to another specific aspect, the pre-fabricated element comprises in the panel at least one stiffener forming a first reinforcing cleat joining the upper rail of the frame to the upper rail of the pre-fabricated element and in that it comprises in the panel at least one stiffener forming a second reinforcing cleat joining the lower rail of the frame to the lower rail of the pre-fabricated element.
According to another specific aspect, the pre-fabricated element comprises in the panel a stiffener forming a door frame positioned around a door opening, wherein the frame comprises an upper rail joined to two lateral posts, wherein the panel further comprises at least one stiffener which forms a reinforcing cleat joining the upper rail of the frame to the upper rail of the pre-fabricated element, wherein the vertical posts are joined by their lower end to the lower rail of the pre-fabricated element.
Another purpose is to create a component element of the roof.
According to this purpose, the pre-fabricated element comprises two pre-fabricated component elements of a well each extended by an oblique panel defined by two incorporated lateral rafters, wherein the two oblique panels join at their summit, and the incorporated cleats and rafters are positioned on one face of their associated panel facing towards the interior or the exterior, to form a pre-fabricated component element of the roof.
Another purpose of the invention is to propose a construction method, for example for houses with wooden structures, for which the fabrication permits savings of raw materials and energy to be made.
Another purpose is that all of the pre-fabricated elements used in this construction method are manufactured more quickly than the elements used according to the known manufacturing methods.
Another purpose is that the assembly step of the pre-fabricated elements is simpler and quicker, compared to the assembly of the elements that are currently used.
These purposes are achieved by a construction method for walls or houses comprising the following steps:
- drying of the wood shavings into laminate boards,
- impregnated gluing,
- orientation of the laminates on the tool,
- compression of the pre-fabricated construction elements,
- baking of the pre-fabricated construction elements,
- assembly of the pre-fabricated elements to one another,
characterised in that the assembly step comprises:
- raising a first pre-fabricated element equipped with a quick attachment hook,
- pushing the first pre-fabricated element towards a second pre-fabricated element, with the hook of the first pre-fabricated element positioned opposite a slot for accommodating the second pre-fabricated element,
- locking the first pre-fabricated element onto the second, by placing the first pre-fabricated element in its stable position.
According to another specific aspect, the compression step comprises the formation of protruding stiffeners on the board forming a frame around an opening.
Another purpose of the invention is to propose an assembly of pre-fabricated elements that form at least part of a house with at least the pre-fabricated component elements of a wall, characterised in that the pre-fabricated wall elements are joined together to form at least one wall of a house, wherein the upper rails of the pre-fabricated elements form at least one horizontal support beam for an upper floor or a roof.
According to another specific aspect, the assembly comprises a lower floor on which rest the pre-fabricated wall elements, wherein the floor comprises pre-fabricated elements that are each made from a single piece of pressed wood by a moulding or extrusion type manufacturing method, wherein each pre-fabricated element that composes the floor comprises a panel joined to a plurality of support elements in the form of stiffeners forming incorporated joists of the same length as the panel and positioned in parallel to one another.
According to another specific aspect, the assembly comprises at least one roof comprising a plurality of component elements of the roof mounted adjacently by their rafters.
The invention, with its features and advantages, will be more clearly understood upon reading the description made in reference to the appended drawings in which:
FIG. 1 shows a perspective view of an example of a wall element according to the invention;
FIG. 2 shows a perspective view of another example of a wall element according to the invention;
FIG. 3 shows a front view of another example of a wall element according to the invention;
FIGS. 4 and 5 show perspective views of quick attachment elements used in this invention;
FIG. 6 shows a perspective view of a wall element comprising a window opening according to the invention;
FIG. 7 shows a perspective view of a wall element comprising a door opening according to the invention;
FIG. 8 shows a top view of an example of a profile of two wall consecutive elements according to the invention;
FIGS. 9 and 10 show perspective views of wall and roof boxes according to the invention;
FIG. 11 shows a perspective view of an example of a palisade element according to the invention;
FIG. 12 shows a perspective view of an example of a floor element according to the invention;
FIG. 13 shows a part of a wall according to the invention;
FIG. 14 shows a perspective view of an example of a wall element according to the invention;
FIGS. 15 and 16 show embodiment variants of construction elements according to the invention.
The invention will now be described in relation to the figures mentioned above. FIG. 1 shows an example of a wall element (1a) according to the invention on which, non restrictively, the surface of the panel (10a), orientated towards the interior of the building, which seals the walls is represented according to a pattern. This same pattern will show, non-exhaustively, in FIGS. 2, 3, 6, 7, 9, 10 and 13 the inside surface of the panels sealing the walls or the roof, so as to make the drawings easier to read. The wall element (1a) has a height (H) which corresponds for example to the height of the ceiling, once the house has been built. The support elements are made in the form of stiffeners incorporated into the pressed wood panel. The stiffeners permit the buckling of panels to be avoided or the bending of a panel. The stiffeners thus stiffen their associated panel.
The wall element (1a) comprises two incorporated lateral cleats (11a), an incorporated upper rail (12a) and an incorporated lower rail (13a), of the same depth (P). The lateral cleats (11a) are joined at one end to the upper rail (12a) and at the other end to the lower rail (13a). The lateral cleats and the upper and lower rails of this wall element (1a) thus form a rectangular frame, closed on one face by a panel (10a). Non-restrictively, the panel is positioned on the external side (EXT) of the building or the house during the construction. The interior (INT) and exterior (EXT) of the house are shown on each side by a dotted line in FIGS. 1 and 2. The empty part of the wall element (1a), in between its frame (11a, 12a, 13a) is for example filled with an insulating material. As the wall element shown in FIG. 1 is composed of its outer frame and a panel joined to one another imperviously, the insulation made is therefore thermal and phonic insulation. Non-restrictively, the sealing panel (10a) is flat, as shown in the example of FIG. 1.
Non-restrictively, the support element is incorporated into a panel that forms surfaces with a long generating line that is parallel to one edge of the panel and that each have a determined thickness.
The manufacture of the pre-fabricated wall element (1a) shown in FIG. 1 is specific to the invention. This wall element (1a) is indeed made in one piece by moulding. This invention is generalised to all of the surfaces covered by panels supported by beams, joists, cleats or any other support posts. These surfaces are advantageously made from pressed wood panels, such as for example recomposed wood. Pressed wood materials are for example composed of a resin loaded with wood shavings or are of the OSB type. The OSB (Oriented Strand Board) type material is made by pressed and oriented wood fibres. The OSB material is advantageously used as it allows construction elements of thinner sections to be used that are consequently lighter. Furthermore, an OSB type construction is cheaper in terms of raw materials. The recomposed wood panels are joined to their support beams, wherein these beams are incorporated with their panel into a same moulded or extruded one-piece element. Different treatments, for example anti-rot, may be carried out on this type of material and are known to a person skilled in the art.
This type of construction element advantageously permits pre-fabricated construction elements to be manufactured without loss, for architectures with wooden structures. Various forms may be made, for example with a decoration.
Furthermore, the resistance of recomposed wood materials, such as the OSB type for example, is known, and the dimensioning of the pre-fabricated elements may be optimised to resist determined stresses, again permitting material to be saved. According to the prior art, raw wood beams are in fact over-sized to include a significant safety margin. The example of the wall element (1a) shown in FIG. 1, should for example support the weight of part of the ceiling and part of the weight of the roof. Its upper beam (12a) will be for example dimensioned like a horizontal beam supported at its two ends. The upper beam (12a) will have for example a cross section determined with respect to its large dimensions (P, L) which correspond to the width (L) and the depth (P) of the wall element (1a). The two lateral cleats (11a) will be dimensioned as two vertical beams supporting the previous horizontal beam. These lateral cleats will have for example a cross section determined with respect to their large dimensions (P, L) which correspond to the height (H) and the depth (P) of the wall element (1a). Furthermore, the sealing panel (11a) partially supports the upper rail (12a).
FIG. 2 is another embodiment of a wall element (1b) according to the invention, which differs from the wall element (1a) shown I FIG. 1, in the form of the sealing panel (10b) and the form of the upper (12b) and lower (13b) rails. The frame (11a, 12b, 13b) of the wall element is similarly joined to the sealing panel (10b) imperviously, wherein the wall element is itself made in one piece, by moulding. Non-restrictively, the profile of the sealing panel (10b) follows a broken line, as shown in FIG. 2, or forms an undulation as shown in the cross sectional view of FIG. 8. This non-straight profile of the sealing panel (10b) especially has improved compression resistance in the direction of its height (H) and especially provides better support for the upper rail (12b). The face of the sealing panel (10b) facing towards the interior of the building will be itself covered by thermal or phonic insulation. The face of the sealing panel, facing towards the exterior of the building, is non-restrictively in contact with an air space circulating in the walls of the house, permitting for example humidity to be evacuated to dry the walls. The undulated or broken line face creates a slight perturbation in the air that does not prevent it from circulating. Advantageously, the external face of a wall element comprises one or several flat spots (14). The insulating wall panel of the building is thus attached against these flat spots (14). Non-restrictively, the insulating wall panel is made using wood siding or comprises a metal structure onto which bricks are placed or a grid onto which concrete is sprayed.
In general, the support elements incorporated into the sealing panels have the advantage that the pre-fabricated elements are quicker to assemble. Pre-fabricated wall elements (1a, 1b) such as for example those shown in FIGS. 1 and 2 will be positioned side by side, with the lateral edge of a wall element in contact with the lateral edge of another wall element. Such a junction between two pre-fabricated construction elements, according to the invention, is for example shown in FIG. 8. They are indeed quicker to assemble, as a person could assemble at the same time the support elements, such as for example the cleats and the sealing elements, such as for example the wall sealing panels. Similarly, the assembly of the floor elements (6) shown in FIG. 12 is quicker and easier as a person could assemble the support joists (62) at the same time to their floor sealing panel (61). According to the example of roof elements (4a, 4b) shown in FIGS. 9 and 10, a person could assemble at the same time the rafters (41) and the roof sealing panels (42). FIG. 14 shows a variant of a wall element (7) comprising a panel (71) with stiffeners (72) which form incorporated cleats positioned in parallel to one another joined to a same panel face. The incorporated cleats are shorter than the panel. The panel thus comprises two flat sections, respectively in an upper and a lower zone, on its face that faces towards the interior of the building, designed to come into contact with an upper wall rail or respectively a lower wall rail. The panel (7) is attached directly with its incorporated cleats (72) to seal a building wall. The assembly time is thus much shorter. This wall element (7) is manufactured for example by moulding or by extrusion.
Non-restrictively, when two elements, such as for example two wall elements, are joined in contact with one another on a flat surface, the junction surface has complementary connecting or sealing forms. Complementary metal connecting elements (7, 8) added to the edges of a pre-fabricated wall element are for example shown in FIGS. 3, 4 and 5. FIG. 3 shows a wall element (1c) comprising on the edge of a lateral cleat, a protruding metal attachment bracket (7) positioned for example in an accommodation recess. On the other cleat, this wall element comprises for example a second accommodation recess suited to house a metal part featuring a slot (8) designed to accommodate an attachment bracket (7). The hook is for example flat with a base positioned at the height of an accommodation slot. The base of the hook extends for example towards the bottom along the lateral edge.
Consequently, two pre-fabricated construction elements associated to two metal attachment parts, as shown on the element of FIG. 3, may be attached to one another. A wall element is for example attached to each of its lateral edges with another wall element or any other construction element comprising the same attachment means. The junction between each of the various male attachment elements (7) with a female attachment element (8) is for example shown in FIGS. 4 and 5. The protruding attachment element (7) is firstly positioned opposite the attachment slot (8), for example by raising the construction element (1c) supporting the male part with respect to construction element supporting the female part. The protruding hook (7) is then introduced into the slot (8) then moved downwards in a translation movement for example by pushing the pre-fabricated construction element (1c) supporting the hook (7) towards the construction element supporting the female part (8) then by resting the construction element (1c) supporting the hook onto the floor, at the same level as the element supporting the female part. Consequently, the construction elements fit into one another, simply by pivoting a construction element and by pushing it towards another to then pivot it into its stable position and then locking the two construction elements together. As the construction elements are made of wood, a single person could move them to place them on a floor.
These attachment elements (7, 8) are quick attachment devices which permit rapid fitting of the various construction elements. Non-restrictively, the metal quick attachment elements lock into place or the definitive attachment is then made by known attachment means such as nails, screws or any other known means. The attachment elements (7, 8) thus facilitate the installation of the walls or the roof while permitting the construction elements to be held together. Furthermore, the right angled junctions of the attachment elements (7, 8) make the structure more rigid.
Non-restrictively, as shown in FIG. 8, the outside edges of the lateral cleats (11d) which join two construction elements (1d) each comprise a complementary surface (810, 710) forming a curved section. In FIG. 8, the edges of the connecting cleats (11d) each form a complementary “S” shape. These surfaces (810, 710) form a curved section and advantageously permit any passage of air between the two construction elements (1d) to be blocked. Indeed, the junction of the two imperfect flat surfaces may allow air to circulate and create a thermal bridge on either side of the construction elements, between the interior (INT) and the exterior (EXT) of the building. The curved section (710, 810) at the junction prevents air from passing.
FIGS. 6 and 7 show other examples of component wall elements (2, 3) according to the invention. FIG. 6 shows for example a one-piece pre-fabricated element (2), comprising a window opening (20) that has been made by moulding. FIG. 7 shows another one-piece pre-fabricated element (3) comprising a door opening (30) that has been made by moulding.
In general, the pre-fabricated elements according to the invention are made of recomposed wood, such as for example of an OSB type material. The construction of pre-fabricated construction elements is then carried out similarly to the manufacture of OSB type “process” panels. The manufacture of pre-fabricated construction elements according to the invention starts by the entry of the wood then the debarking of the wood. The wood is then cut into laminates that are dried by quick drying in barrels. The dried laminates are then glued by impregnation then oriented on a tool and shaped. Compression and baking complete the manufacturing process of the construction elements before the finished product is evacuated. Non-restrictively, the construction elements are shaped by extrusion or moulding.
The manufacturing process of the pre-fabricated construction elements according to the invention has the advantage of being much quicker than a manufacturing process of the prior art. Indeed, in the prior art, the support elements, such as the posts and rails, made of solid wood, required much a longer drying time for the solid wood, contrary to this invention. The loss of time in machining was even more consequent as the manufacture of simple OSB panels was also required in the prior art.
Furthermore, in the prior art, the machining of the support elements to the correct dimensions caused waste and therefore a loss of raw material, as opposed to this invention wherein the use of the raw material is maximised. Similarly, in the prior art, planning after drying of the rough wood then cutting to the correct dimensions also caused a loss of raw material, contrary to the manufacturing process of this invention.
Finally, the manufacturing process of the pre-fabricated construction elements of this invention is much simpler and quicker as the pre-fabricated elements are made in one piece, by moulding or extrusion. Thus advantageously, part of the assembly of the prior art, for example of panels with cleats, is avoided, which permits a saving of human resources. Moreover, errors during assembly and the associated losses are also avoided. Again, the invention permits an economical production in terms of energy and raw materials which is therefore more ecological.
The example of the wall element shown in FIG. 6, advantageously comprises a window opening (20) defined by a frame comprising an upper rail (201) and a lower rail (202) and two lateral posts (203). The elements (201, 202, 203) of the frame are an integral part of the wall element (2) that is made from one piece. Similarly, this wall element (2) is defined by lateral cleats (212), a lower rail (213) and an upper rail (211). Vertical reinforcing cleats (222 and respectively 221) support the window frame joining the upper (211) and lower (213) rail of the element (2) to the rails (201 and respectively 202) of the window frame. This pre-fabricated wall element (2) is sealed by a panel (23) joining its external frame to its window frame (203, 202, 201) and also joined to the reinforcing cleats (221, 222). This pre-fabricated element (2) thus forms a one-piece assembly made for example by moulding. Non-restrictively, the sealing panel (23) is undulated so that it is more rigid. This pre-fabricated wall element (2) which comprises a window opening (20) will be positioned for example on a floor, on its lower rail (213). Its lateral posts (212) will be in contact with other pre-fabricated wall elements (1b, 2, 3, 4a) and its upper rail (211) will form part of the horizontal beam, at the height of the ceiling. Consequently this pre-fabricated element (2) comprising a window opening (20) is assembled with the other pre-fabricated elements and is for example equipped at the external edges of its lateral cleats (212) with quick attachment elements or curved sections.
Another pre-fabricated one-piece element (3) that may form part of a wall of a house is shown in FIG. 7. This element (3) which comprises a door opening (30) is assembled with the elements shown in FIG. 6, 1, 2 or 3. The pre-fabricated element (3) comprising a door opening (30) defined by a door frame comprising an upper rail (301) supported at its ends by two lateral posts resting on the lower rail (23) of the prefabricated element (3). The element (3) is defined by lateral cleats (33) for example equipped with quick attachment elements or curved sections and joined to other pre-fabricated component wall elements. An upper rail (31) of the pre-fabricated element (3) comprising the door opening is supported by the lateral cleats (33) and, non-restrictively, by an undulated sealing panel (34). The upper rail (31) permits a horizontal beam type support at ceiling level. The upper rail (31 of this element (3) is joined by reinforcing cleats (311) to the upper rail (301) of the door frame. Each of the component elements of the pre-fabricated element comprising the door opening (30) are an integral part of this element (3), made in a single piece for example by moulding.
FIGS. 9 and 10 are two examples of pre-fabricated elements (4a, 4b) forming a wall element extended by a roof element. These elements (4a, 4b) are made in one piece and comprise for example panels (43) for sealing the wall that are laterally defined by incorporated cleats (44) and panels (42) for sealing the roof that are defined by incorporated rafters (41). Non-restrictively, the cleats (44) and the rafters (41) are made so that they face towards the exterior of the building, as shown in FIG. 10, or towards the interior of the building as represented in FIG. 9. Non-restrictively, the wall elements (44, 43) extended by the roof elements (41, 42) comprise, as previously described, window openings and door openings. As in the previous description, these elements (4a, 4b) rest on a floor and are joined to one another at their lateral edges, equipped for example with quick attachments or curved sections.
FIG. 12 shows a pre-fabricated floor element (6). Advantageously, this element (6) comprises a panel (61) for covering the floor associated to incorporated joists (62). Advantageously, it is quicker to fit. The use of incorporated joists (62), for example made of OSB, advantageously permits raw material and time to be saved in comparison to the machining of joists from rough wood, according to the prior art. Furthermore, the form of the pre-fabricated floor elements (6) according to the invention provides them with better rigidity than simple “process” panels. The floor element (6) is for example made by moulding or extrusion.
FIG. 11 shows a pre-fabricated enclosure element (5) according to the invention, made by moulding or extrusion. This pre-fabricated element comprises a sealing panel (51), joined to two incorporated vertical posts (52) which cover the entire height of the panel (51). The posts (52) which extend below than the panel (51) may be planted in the ground. Non-restrictively, a plurality of enclosure elements, with incorporated legs, is placed on the ground or in the ground, side by side, to form an enclosure. In another example of use, this pre-fabricated element (5) is used alone as a sign post.
An example of the assembly of several elements is shown in FIG. 13. An element (2) comprising a window opening (20) is placed on a floor (6) and against a wall element (1b). The wall element (1b) is aligned against an element (3) comprising a door opening (30), to extend the wall. The upper parts of the elements (2, 1b, 3) form a horizontal support beam, for example for a floor or for a roof.
According to one variant, shown in FIG. 16, a panel (81) is extended by incorporated legs (82), wherein the legs cover the entire height of the panel (81), to form a pre-fabricated construction element (8) that is a component of a palisade or to for a sign post. This pre-fabricated element (8) is made from one piece for example by a process such as moulding or extrusion.
According to one embodiment, shown in FIG. 15, a pre-fabricated element (1e) that is a component of a wall of a building comprises a panel (10e) whose edges are extended by incorporated lateral posts (lie), in the form of vertical cleats positioned towards the exterior (EXT) of the building to support an insulating wall panel of the building. The lateral posts (lie) are joined at their ends to an incorporated upper rail (12e) and to an incorporated lower rail (13e) which extends the upper and lower edges of the panel (10e). This element (1e) has, towards the interior (INT) of the building, a flat face designed, non-restrictively, to be coated for example with plaster. According to one embodiment of this component element (1e) of a wall, cleats are attached, for example by nails, onto the flat face positioned towards the interior (INT) of the building, wherein an insulating material is then added between the cleats and the interior wall of the building is then attached to these cleats. Non-restrictively, this component element (1e) of a wall is manufactured in the same way as the element (1a) previously described and shown in FIG. 1.
It should be obvious to a person skilled in the art that the present invention permits embodiments in many other specific forms without this leaving the scope of application of the invention, as claimed. Consequently, the present embodiments should be considered as illustrations, which may be modified to suit the field defined by the attached claims, and the invention should not be restricted to the details provided above.
Patent Application
20090205287
