NZ503003A - Building module consisting of panels spaced by framing members that project out and interlock with adjacent members when panels assembled - Google Patents

Abstract

Modules 1, 2, 3,4, 5 are stacked vertically on assembly. Framing members are located between panels and protrude above and below them, so as adjacent modules have overlapping framing members.

Description

Patents Form No. 5 Patents Act 1953 COMPLETE SPECIFICATION SET OF BUILDING MODULES I, Katherine Gail Duncan, a New Zealand citizen of 81 Tomes Road, Christchurch, New Zealand hereby declare the invention for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement: Intellectual Property Office of NZ 1 2 1 FEB 2001 The present invention relates to a set of building modules capable of assembly into a load bearing and bracing interior or exterior wall, and to a wall assembled from these modules.

Background Art Conventional building techniques for constructing load bearing walls generally involve skilled onsite work and repeated careful measurement to ensure that the walls are correctly built and vertical, and corners are square. There is therefore a demand for modular constructions which can reduce the requirement for skilled onsite labor and 10 thus make wall assembly quicker and/or cheaper, and yet produce a satisfactory result.

Numerous proposals have been made in the last century or so, in attempts to overcome this problem, but many of the proposed structures have been suited only to particular types or styles of building, or have sacrificed strength for ease of 15 construction. It is therefore an object of the present invention to provide a set of building modules, which are versatile in their application, cheaper to construct, and easy to use onsite, but which never-the-less can be assembled to provide a reliably strong and well braced load bearing wall. It is a further object of the present invention to provide a set of building modules which, when assembled into a wall, provides a 20 rigid surface to which finishing can be directly applied.

Another object of the present invention is to provide a building module which is capable of being assembled into a wall in which the modules are positively interlocked with each other, thus creating a structure which is plumb, square and integrally braced, and 25 which is very stable in high winds or earthquakes.

Disclosure of Invention The present invention provides a set of building modules, each building module in the 30 set comprising two parallel panels secured to and spaced apart by framing members which are spaced apart along the length of said panels; wherein in at least one of said modules in the set one or more of said framing members protrudes above and/or below said panels in a plane parallel to the planes of said panels; and wherein the building modules in the set are adapted to be stacked one on top of the other with the 2 planes of said panels and the plane of said framing member substantially vertical; the framing members of the modules in the set being located and arranged such that when the modules of the set are stacked, the modules are interlinked by one or more protruding framing members extending between the panels of adjacent modules and 5 overlapping one or more corresponding framing members of said adjacent modules.

Preferably, each module of the set includes one or more protruding framing members. However, some of said framing members may be shorter in height than the panels between which they are secured.

Preferably, each set includes at least three modules and the framing members are arranged such that when the modules of the set are stacked, the overlapping framing members overlap on alternate sides so as to restrain racking of the set.

In one preferred embodiment of the invention, the framing members of the module in the set are located and arranged such that when the modules of the set are stacked, at least one framing member of each module butts against a framing member of the or each adjacent module so as to form a composite continuous framing member extending the full height of the set.

In second embodiment of the invention, preferably at least one framing member of at least one of the modules in the set extends over the full height of the set of modules when the modules of each set are stacked.

Preferably also in said second embodiment, the set of modules comprises three modules; an upper module, a lower module and a centre module, with the or each said full height framing member secured to said second module.

The panels and the framing members may be made of any suitable materials e.g. 30 concrete, metal, or suitable plastics materials. Preferably, however, the panels are made of ply and the framing members of timber.

Intellectual Property Office of NZ MAR 2001 received Brief Description of Drawings Byway of example only, preferred embodiments of the present invention are described in detail with reference to the accompanying drawings in which: - Fig. 1 is an isometric view, partly exploded, of part of two walls meeting at a corner, constructed from modules in accordance with a first embodiment of the present invention; Figures 2a-2b - Figures 6a-6b inclusive are respectively side views and plan views of different configurations of building module in accordance with a first embodiment of the present invention; Fig. 7 is a front view of a wall constructed from modules in accordance with a second 15 embodiment of the present invention; Fig. 8 is an isometric exploded view of a corner formed between two walls in accordance with said second embodiment; and Fig. 9 is an isometric exploded view of the junction between an exterior wall and an interior partition wall, in accordance with said second embodiment.

Best Modes of Carrying Out the Invention Referring to Fig. 6a, 6b, the basic module 12 comprises two flat panels 13, 14 parallel to each other, the panels being spaced apart by, and secured to, a series of framing members 15. Each of the panels 13,14 is rectangular and the framing members 15 are rectangular in cross-section. Preferably, the panels 13, 14 are made of exterior grade ply and the framing members 15 of timber. The framing members and panels may be 30 secured together by any suitable means e.g. nailing, screwing or gluing.

The number of framing members 15 used in each module, and the distance between adjacent framing members 15 in a particular module, both depend upon the intended purpose of the module: - a module intended to form part of a lightly loaded wall may 35 require only two framing members, whereas a module intended to form part of a wall Intellectual Property * Office of NZ 21 FEB 2001 RECEIVED which will carry a very heavy load, or for which great rigidity is required, may use a plurality of closely spaced framing members 15.

As a general principle, the framing members 15 are positioned such that when the 5 modules 12 are assembled together as hereinafter described, the framing members 15 of adjacent modules 12 not only extend between the panels of the adjacent module but also contact the framing members of the adjacent module: - some of the framing members 15 are arranged to abutt framing members of the modules above and/or below (i.e. contact said members end on), so as to form a continuous load bearing 10 beam structure; others of the framing members overlap the side of a framing member in the module above or below, locking the two modules together and preventing sideways movement (racking) of adjacent modules. As used herein, the term 'overlap' means that part of one frame member overlies and contacts part of the other framing member.

A typical corner structure formed by two walls meeting at right angles is shown in part in Fig. 1.

Two base modules 1,4, are used both of which are secured to foundations in any 20 suitable known manner (not shown). The base module 1 is shown in detail in figures 2a and 2b and consists of two spaced panels 17 secured to, and spaced apart by, four framing members 19-22 inclusive.

The framing members 19,21 and 22 are the same height as the panels 17; the framing 25 members 19,22 are secured at the opposite ends of the module, and the framing member 21 is slightly offset from the midpoint of the module. The framing member 20 is much shorter in length and projects upwards from the upper edge 23 of module 1.

The base module 4 is shown in detail in figures 3a and 3b and consists of two spaced 30 panels 24 secured to, and spaced apart by, six framing members 25, 26, 27, 28, 28a and 29. The framing members 25, 26 and 28, 29 are paired at each end of the module to form square posts, which extend to approximately half the height of the module. The framing member 27 extends the full height of the module and is slightly offset from the midpoint of the module. The framing member 28a extends the full height of the module 35 and lies alongside the framing member 28.

Intetlectual Property Office of NZ 21 FES 2001 To form the first stage of the corner, the ends of module 1 and module 4 are butted together at right angles as shown in Fig. 1, and secured in positioned by nailing into the framing member 19 at the end of module 1, through the side of the panel 24 of module The corner structure is then locked together by lowering module 3 into position. Module 3 is shown in figures 4a and 4b and consists of two spaced panels 30 secured to, and spaced apart by, seven framing members 31, 32, 33, 34, 35, 36 and 37. As with 10 module 4, the framing members 31, 32 and 35, 36 of module 3 are arranged in pairs at each end of the module to form square posts which extend approximately half the height of the module; however in the case of module 3, these square posts also extend the same distance below the lower edge of the module.

Framing member 33 is located just off the midpoint of the module and has a length equal to the height of the module but is secured so half its length projects below the lower edge of the panels 30. Framing member 34 is a short stub which is secured midway between the framing members 33 and 35 and extends a short distance below the lower edge of the panels 30. Framing member 37 extends the full height of the 20 panels 30, lying alongside the framing member 32.

When the module 3 is lowered into position as shown in Fig. 1, the framing members 31,32 abutt the framing members 28,29, forming a continuous load bearing member. It is envisaged that it may be advantageous to provide one or more outwardly extending 25 dowels or pegs which extend outwards from the end of one of the pairs of framing members 28,29/31,32 and to provide corresponding holes for a set of these dowels or pegs on the other of the pair of framing members 31,32/28,29, to positively key the framing members in the correct position. The framing member 28a overlaps the side of the members 31,32 and locks those members in position. The framing members 33 30 and 34 of module 3 extend downwards between the panels 17 of module 1, with the side 34 a of framing member 34 overlapping and pressing tightly against the corresponding side of the framing member 21 of module 1. The end framing members 35,36 of module 3 extend down between the panels 17 of module 1. Since the panels 17,30 of modules 1 and 3 respectively are the same length, but the module 3 extends 35 over the corner end of module 1 when locked into position, a gap 39 is formed at the 4. intellectual Property Office of NZ 6 2 1 FEB 2001 other end of module 1 to receive a further framing member from the next module in line adjacent module 3, to lock that joint in position also.

The next module to be positioned is module 2, which rests on top of module 4. Module 5 2 is shown in figures 5a and 5b and consists of spaced panels 40 secured to, and spaced apart by, four framing members 41, 42, 44, and 45. The framing members are of varying lengths; some protrude below the lower edge of the panels 40 and framing members 42 and 45 also project above the upper edge of the panels 40. The framing member 41 is spaced a short distance from the end of the module 2 furthest from the 10 corner, and projects downwards between the panels 24 of the module 4. The framing member 42 is located so that it overlaps one side 27a of framing member 27 of module 4 and thus prevents any racking of the module 2 in one direction. When the next module 5 (shown only in part in figure 1) is positioned on top of module 2, framing member 50 is positioned so as to overlap face 42a of framing member 42 and thus 15 prevent any racking of module 2 in the opposite direction. Framing member 44 extends between the panels 24 of the module 4.

The module 5 completes the locking of that section of the corner, since framing member 51 at the corner end of module 5 is positioned to overlap framing member 45 20 and to be socketed in the aperture 30a between the panels 30 of module 3 and the framing member 37.

At the end of module 2 adjacent the corner, the outer panel 40a is full-length but the inner panel 40b terminates at the framing member 45; the panel 40b is shorter than the 25 panels 40a by a distance equal to the thickness t of the module, so that when the modules are assembled as shown in Fig. 1, the panel 40a fits across the end of module 3.

It will be appreciated that the above-described modules may be varied as necessary to 30 suit a variety of applications. The modules are shown in the drawings as all having approximately the same height, but this may of course be varied to suit circumstances. The stub framing members such as 44 and 34 principally serve to stiffen the joint between adjacent panels, so that the assembled wall can have finishing materials applied directly over the panels. The completed wall formed from the modules of the 35 present invention is braced diagonally due to the overlapped framing members and Intellectual Property 7 Office of NZ 21 FEB 2001 RECEIVED carries the load upon the framing members rather than upon the panels due to the abutted vertically aligned framing members.

The manner in which the modules forming the corner are locked into position ensures 5 that the corner is perfectly square and perpendicular without additional measurement being required during construction. Although a two wall corner has been shown by way of example, it will be appreciated that the same principles are applied to forming a four wall corner.

If necessary, all of the vertically aligned framing members may be further tied together by forming through holes through the framing members to allow tie rods or tie ropes to be inserted after assembly.

Referring now to figures 7-9 of the drawings, in a second embodiment of the present 15 invention the centre module 60 of each set has a height h approximately three times greater than the heights b and t of the lower and upper modules 61,62 respectively.

Each of the modules 60,61,62 is constructed in the same general manner as described with reference to figures 1-6 , i.e two flat panels parallel to each other, the 20 panels being spaced apart by, and secured to, a series of spaced framing members.

In each centre module 60, the framing members 63 (shown in broken lines in figure 7) extend beyond the upper and lower edges of the panels 64 to the full height of the assembled set of modules (i.e t +h +b). Thus, in each assembled set of modules, the 25 framing members 63 provide continuous support for the full height of the set.

In each lower module 61, each framing member 65 (shown in dotted lines in figure 7) extends vertically above the upper edge of the panel 66. In each upper module 62, each framing member 67 (shown in dotted lines in figure 7) extends vertically below 30 the lower edge of the panel of 68.

To erect the above described modules into a wall, as shown in figure 7, first the lower module 61 is secured to a foundation or other suitable supporting surface in known manner, with the framing members 65 extending vertically upwards. Next, the centre 35 module 60 is lowered into place on top of the lower module 61 and is positioned so 8 2 1 FEB 200! that the lower end of the framing members 63 overlap the framing members 65. In the particular wall shown in figure 7, the lower module 61 and the centre module 60 are formed in two parts, to form a doorway 70 in the completed wall.

To complete the wall, the upper module 62 is lowered onto the top of both parts of the module 60, with the framing members 67 overlapping the upper end of the framing members 63. The framing members 67 are offset relative to the framing members 65 so that at least some of the framing members 67 lie on the opposite side of the framing members 63 to the framing members 65. Thus, once the wall has been completed, 10 some of the framing members 63, and hence the whole of the centre module 60, are laterally braced against racking. Also, on each wall, or section of wall if a wall broken by an aperture such as the doorway in Fig. 7, at least one pair of the framing members of the lower and upper modules are arranged opposite each other, e.g. lower module framing members 65a/65b and 65c/65d and upper module framing members 67a/67b 15 and 67c/67d. These opposed pairs of framing members prevent the centre module 60 from racking relative to the upper or lower modules, i.e. moving in the direction of arrows A.

Along the margins of window or door apertures where the framing members 67 or 65 20 are repositioned as necessary to prevent their intruding into the door or window aperture.

As shown in figure 7, the framing members 63 are cut if necessary to prevent intrusion into a window aperture 71.

It will be appreciated that the construction of this embodiment is simpler than that of the first-described embodiment in that the centre module 60 forms of the major portion of the height of the wall, so that there are only three modules to assemble rather than a large number of modules. Further, the construction is stronger because of the use of 30 the continuous full height framing members 63.

Corners and partition walls are formed in a broadly similar manner to the first-described embodiment, as shown in figures 8 and 9.

Referring to Fig. 8, on the right hand side of the corner the lower module 75 has its Intellectual Property 9 Office, of N2 21 FEB 200! RECEIVED panels ending flush with the outer surface of the last framing member 76. On the left hand side of the corner, the lower module 19 has its last framing member 91 set back from the corner by distance approximately equal to the thickness of the framing member 80 of the right hand centre module 81. The framing member 80 is located at 5 the outer edges of the panel of the centre module 81, so that when the centre module 81 is positioned on top of the lower modules 75/90, the framing member 80 fits into a socket 92 formed by the outer edges of the panel 93 of the module 90 and an end panel 94, with the framing member 91 overlapping one side of the framing member 80, and the framing member 76 overlapping the other side.

The left hand centre module 77 has its outer panel 78 extended so as to cover the outer surface 79 of the adjacent framing member 80 of the right hand centre module 81.

The framing member 82 of the module 77 is set back from the edge of the module so that when the centre module 77 is lowered on to the corresponding lower module 90, the lower portion 82a of the framing member 82 overlaps the side 91a of the framing member 91.

The upper modules 95/83 are formed in a similar manner to the lower modules:- when the corner is assembled, the upper portion of the framing member 80 fits in a socket 97 formed by the ends of the panels of the module 95 and an end panel 78. The left hand upper framing member 96 fits between the framing members 80 and 82, and the left hand upper framing member 84 overlaps the opposite side of the framing member 25 80 to the framing member 96.

When the above described modules are assembled, each of the framing members 80,82 is securely connected to the corresponding upper and lower modules and the corner has a uniform outer finish formed by the end panels 98 and 94 and the outer 30 panel 78. The corner is secured by nails, screws or bolts in known manner.

Figure 9 shows a joint between an interior wall 100 and an exterior wall 101, with a doorway 102 on the left-hand side of the joint, so that only the right-hand side of the exterior wall 101 is visible .

Intellectual Property Office of NZ 21 FEB 2001 The lower module 103 of the exterior wall 101 has its outer edge closed by an end panel 104 which with the end framing member 106 of the lower module 103 forms a socket for receipt of the lower end of the framing member 105 of the centre module 111 of the interior wall. The lower end of the framing member 107 of the centre 5 module 108 of the exterior wall 101 overlaps the opposite side of the framing member 106 to the framing member 105.

The lower module 109 of the interior wall 100 terminates in a framing member 110 which extends between the panels of the centre module 111 of the interior wall; the 10 end 112 of the lower module of the interior wall lies flush against the side of the lower module of the exterior wall.

The upper ends of the framing members 105 and 107 of the centre modules of the interior and exterior walls respectively are received between the panels of the upper 15 module 114 of the exterior wall, one on each side of a framing member 113 of said upper module. The upper module of the interior wall is arranged in a similar manner to the lower module, and ends flush against the side of the upper module 114 of the exterior wall, with its end framing member 115 received between the panels of the centre module 111 of the interior wall. The joint is secured by nails, screws or bolts in 20 known manner.

It will be appreciated that the above described configurations may be varied extensively to suit particular circumstances:- for example, more or fewer framing members can be used depending upon the desired strength of the structure, and the 25 size and relative proportions of the upper, lower and centre modules also can be varied as necessary. Further, the configurations of corners and interior walls described with reference to figures 8 and 9 are only two of a wide variety of different configurations which can be adopted within the scope of the present invention.

In the above described embodiments, most of the overlapping framing members are depicted as projecting beyond the panels to which they are secured. However, it is possible to achieve an equivalent effect even if only one framing member of each pair of overlapping framing members projects beyond the associated panels, always provided that there is sufficient overlap between the framing members for lateral 35 support.

Intellectual Property ii Office of HZ 21 FEB 200! If panel sections need to be joined to make the required length of a module, the joint may be covered by a suitable trimming strip. The completed structure can be used as is, possibly with the addition of a suitable paint or other sealant finish, or a finish such 5 as plaster can be applied directly to the walls.

Door and window apertures can simply be cut through the panels and protected by conventional door and window frames, or the apertures can be protected by framing members positioned around the edges of the apertures.

A building using the sets of modules of the present invention can be erected rapidly and accurately even by unskilled labour, because of the interlocking of the corresponding modules, which automatically produces a plumb, square braced structure. 12 '•lectual Property Office of NZ 2 1 FEB 2001

Claims (14)

1. A set of building modules, each building module in the set comprising two parallel panels secured to and spaced apart by framing members which are spaced apart 5 along the length of said panels; wherein in at least one of said modules in the set one or more of said framing members protrudes above and/or below said panels in a plane parallel to the planes of said panels; and wherein the building modules in the set are adapted to be stacked one on top of the other with the planes of said panels and the plane of said framing member substantially vertical; the framing 10 members of the modules in the set being located and arranged such that when the modules of the set are stacked, the modules are interlinked by one or more protruding framing members extending between the panels of adjacent modules and overlapping one or more corresponding framing members of said adjacent modules. 15

2. The set of building modules as claimed in claim 1 wherein each module of the set includes one or more protruding framing members.

3. The set of building modules as claimed in claim 1 or claim 2, wherein the set 20 includes at least three modules and said framing members are arranged such that when the modules of the set are stacked the overlapping framing members overlap (as herein defined) on alternate sides, so as to restrain racking of the set.

4. The set of building modules as claimed in any one of the preceding claims wherein 25 some of said framing members are shorter in height than the panels between which they are secured.

5. The set of building modules as claimed in any one of the preceding claims, wherein the framing members of the modules in the set are located and arranged 30 such that when the modules of the set are stacked, at least one framing member of each module butts against a framing member of the or each adjacent module, so as to form a composite continuous framing member extending the full height of the set. Intellectual Property Office of NZ 2 0 MAR 2001 RECEIVED

6. The set of building modules as claimed in any one of claims 1 - 4, wherein at least one framing member of at least one of the modules in the set extends over the full height of the set of modules when the modules of each set are stacked. 5

7. The set of building modules as claimed in claim 6 wherein said set comprises three modules: an upper module, a lower module and a centre module.

8. The set of building modules as claimed in claim 7 wherein some of the framing members of the upper and lower modules overlap a first side of the corresponding 10 framing members of the centre module and some of the framing members of the upper and lower modules overlap the opposite side of said corresponding framing members of the centre module, so as to restrain racking of the set.

9. The set of building modules as claimed in claim 7 or claim 8 wherein the or each 15 said full height framing member is secured to said centre module.

10. The set of building modules as claimed in claim 9 wherein said centre module has a height equal to at least twice the height of either the upper or the lower modules. 20

11. A wall constructed from a set of building modules as claimed in claim 3.

12. A wall constructed from a set of building modules as claimed in claim 8.

13. A building shell comprising at least four connected walls each constructed from a 25 set of building modules as claimed in claim 3.

14. A building shell comprising at least four connected walls each constructed from a set of building modules as claimed in claim 8. END OF CLAIMS Intellectual Property Office of NZ 20 MAR 2001 14