RU2784512C2 - Construction system for building module - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: present invention relates to a construction system for a building module, main elements of which are made of recycled plastic material, and which is suitable for simple and fast production of a strong structure. The system contains a set of main beams, which can be end-to-end mounted to form a lattice structure in the form of a three-dimensional rectangular frame. The system additionally contains intermediate secondary beams, which can be mounted between parallel and opposite main beams, and flat facade elements, which can be inserted one to the other between two adjacent parallel beams. Each facade element contains a flat rectangular panel having two opposite bent edges designed to engage with adjacent parallel beams. Each main beam has a rectangular cross-section and, on all four sides, has a protruding part parallel to the side, and it is located at a distance from it, so that there is a hole for accommodation of the bent edge of the flat facade element. Each secondary beam has at least one protruding part on at least two opposite sides, wherein these parts leave a hole for accommodation of the bent edge of the flat facade element. The assembly of a building module and a building are also described.

EFFECT: obtainment of a construction system for a building module.

12 cl, 10 dwg

Description

The present invention relates to a building system for a building module, in particular a living space or a garage, the main elements of which are made of a plastic material.

It is already known from the prior art to package products for creating assemblies made essentially from a plastic material. WO 0212077 describes a bottle made from a molded plastic material containing a connector so that the bottle can be connected side by side with another bottle by means of a connector such as a dovetail connection. The bottles can also be stacked on top of each other, thus allowing bottle assemblies to be made.

Also known is WO 2012045061 which describes devices and containers which are extensible, modular and can be laterally and vertically coupled with other similar containers for various applications.

Individuals are also known to have undertaken and carried out the construction of structures such as houses based on plastic bottles, and in most cases the bottles were placed horizontally.

Traditional building systems based on bricks, for example, are also known and very common, but the cost of construction remains significant.

Moreover, the Applicant applied for patent no. CH 707115 related to a bottle adapted to be assembled with other bottles in order to make a structure. These bottles are shaped with a frustoconical male/female portion.

The Applicant has also filed another patent application no. CH 708086 related to a bottle containing in its upper part a male cylindrical double neck containing a first mechanical joint means that can be driven by rotation. The bottom of the bottle contains a cylindrical double neck containing a second mechanical joint means that can be driven by rotation and which is complementary to said first mechanical means for actuating. The top of the bottle can be joined to the bottom of another bottle by the double action of the male and female necks to bring the respective abutment surfaces into contact. The bottle has at least one longitudinal female opening on its periphery, allowing the insertion of an intermediate rod, said rod serving as a link between two bottles placed next to each other, or between the bottle and another structural element with a longitudinal female opening.

These two patent applications are based on mounting bottles of a specific shape to form a rigid formwork, possibly with increased rigidity and improved sealing.

Document WO 2016016706 describes a building system comprising a set of auxiliary elements and a set of elongated housings intended to manufacture a structure by mounting a plurality of said housings with auxiliary elements. The elongated housing comprises a front surface and a rear surface that are planar and opposite, an upper surface and a bottom surface that are planar and opposite, and two opposite side surfaces. At least one of said two side surfaces has a recessed part, in particular a curvature in its central part. Each housing can be mounted with another housing so that their side surfaces are between them, and / or by mounting the bottom surface of one housing with the top surface of another housing, and / or by mounting the side surface of one housing with the front or rear surface of another housing. Auxiliaries are elongated parts that are inserted between and in contact with the recessed parts of two surface-mounted elongated bodies and which extend over the entire height of the elongated bodies or over a significant part of it. In the case of hollow elongates, or when these elongates interact with surface-to-surface mounted elongate body recesses, the elongates themselves define a central space located between and in the middle of the elongate body recesses. The elongated parts further define lateral spaces between the side surfaces of the recessed parts of the elongated bodies on either side of the elongated parts.

Documents EP 0 320 745 A1 and EP 1 321 592 A1 describe building systems, the main elements of which are made of plastic materials, containing beams with a rectangular cross section with profiles of different shapes.

Furthermore, building systems are known which consist of parts made from plastic materials but which are intended for the construction of small models.

The present invention makes it possible to produce a building system for a building module, the main elements of which are made of plastic material, in particular recycled plastic material, allowing a very simple and very fast production of a solid structure.

In accordance with the present invention, this object is achieved by a building system for a building module, in particular a dwelling or a garage, the main elements of which are made of a plastic material, comprising a set of extruded main beams with a hollow profile, having an elongated rectilinear shape, having a rectangular constant cross-section and of the correct length. These main beams are adapted for end-to-end mounting to form a rectangular or cubic lattice structure in the form of a three-dimensional rectangular or cubic frame. The building system further comprises a plurality of intermediate secondary beams adapted for installation between parallel and opposite main beams of a rectangular frame, and a plurality of flat facade elements, made with the possibility of insertion on top of each other between two adjacent parallel beams, each external or internal facade element containing a rectangular flat a plate provided with two bent opposite edges designed to engage with adjacent parallel beams.

In the system according to the present invention, each main beam with a rectangular cross-section contains on its four sides a ledge parallel to the side and spaced from the part of the side located in the direction of its central part, leaving an opening in the direction of each corner of the main beam to receive the folded edge of the flat facade element.

Each secondary beam contains at least one protrusion on at least two opposite surfaces, leaving an opening for accommodating the bent edge of the flat facade element.

Preferably, parallel projections on each side of the rectangular section of each main beam extend beyond the adjacent side of the rectangular section. Also, each main beam preferably comprises on each side two protrusions parallel to and spaced from the side, the two protrusions being separated by a central opening.

In one embodiment, the secondary beams comprise a central hollow core, preferably square, and projections extending on either side of that hollow core to define at least one opening on each side to receive the folded edge of the flat façade element. Preferably, each side of the hollow interior of the secondary beam comprises a central ridge defined by two side ridges defining two openings between them to receive the folded edge of the flat façade element. In one embodiment, the two side protrusions contain at their outer end an edge that is bent outward and recessed relative to the outer end of the central protrusion by a distance that corresponds to the thickness of the flat facade element. Optionally, the outer edges of the hollow interior contain reinforcing profiles.

In the system according to the present invention, the main beams can be mounted using corner pieces located between adjacent ends of the main beams. These corner pieces may comprise a square bar which is shorter than the main beams and which is insertable into the end of the first main beam. One end of this rod contains a longitudinal groove located in the center of each surface of the square rod and designed to accommodate a protrusion on the transition element, made with the possibility of insertion into the end of the second main beam, which can be mounted end to end with the first.

Each rectangular lattice structure in the form of a three-dimensional rectangular frame can constitute a building module that can be assembled with another module, with the dimensions of each module ranging from 2.5 m to 4.5 m in length and side width and from 2.5 m to 3 .5 m in height.

Optionally, flat façade elements contain extractable areas in their flat slabs for creating openings.

In one embodiment, the outer and inner flat façade elements comprise two flat slabs spaced apart to form a formwork. The boards can be screwed, riveted or glued to the main beams and secondary beams.

For greater rigidity, each beam, and optionally the formwork of each façade element, is filled with a substance designed to strengthen their structure, for example, soil mixed with hardening resin, cement, concrete, loam or any other hardening substance, or even a porous material, such as rigid foam.

Preferably and for environmental reasons, the building system is made from recycled plastic materials.

Another aspect of the present invention is an extrusion process for making a system in a carbon dioxide atmosphere in a subcritical cycle or with a hardening agent.

The present invention also relates to a building module assembly of a building constructed from a building system according to all of its described variants, the assembly comprising:

a. at least one building module consisting of a three-dimensional rectangular or cubic framework of the main beams,

b. assembly of secondary beams between parallel main beams and

c. an assembly of flat façade elements inserted between two parallel beams, the folded edges of the façade elements being inserted into said parallel holes.

In an embodiment of the present assembly, the secondary beams are arranged vertically, parallel to and between the vertical main beams, and the façade members are stacked on top of each other between the two vertical parallel beams.

In such an assembly, when the elements of the corner assemblies are compacted to the ground, the flat façade elements have a resistance to a wind load of at least 160 kg/m ² , withstand ground loads of at least 224 kg/m ² , and withstand loads on the top of the module, constituting at least 107 kg/m ² .

When the second building module is placed on the first building module, the elements of the corner assembly of the first building module are compacted on the ground, the flat facade elements are resistant to wind load of at least 182 kg/m ² , withstand ground loads of at least 224 kg /m ² and flat facade elements of the second module withstand loads on the upper part of the specified second module, constituting at least 107 kg/m ² .

In these assemblies, the top of the living space module can be made airtight either by installing flat façade elements or by placing a tarp onto which a polymerization resin can be applied to make said tarp stiff and waterproof.

In another embodiment, the top of the living space module can be made airtight by adding a traditional roof.

This assembly usually constitutes an element of a residential development, for example, a garage, a house. Therefore, the present invention also covers a building, in particular a residential area, such as a house or a garage, containing such an assembly.

The features of the present invention will become more apparent upon reading the following non-limiting description of several embodiments, given by way of example only, with reference to the schematic figures, in which:

- in Fig. 1 is a partial perspective view of the main beam;

- in Fig. 2 is a partial perspective view of the secondary beam;

- in Fig. 3 is a perspective view of a part for joining the main beams;

- in Fig. 4A is a perspective view of an unassembled transition piece between the main beam and the secondary beam;

- in Fig. 4B is a perspective view of FIG. 4A assembled;

- in Fig. 5 is a perspective view of the façade element;

- in Fig. 6 is a perspective view of a part for joining a main beam, such as a horizontal beam, and another part for joining a main beam, for example, a vertical beam;

- in Fig. 7 is a perspective view of a finishing element that can be placed on the piece to join the main beams;

- in Fig. 8 is a partial perspective view of a building module assembly according to the present invention;

- in Fig. 9 is a perspective view of the building module without the top; and

- in Fig. 10 shows two living room modules according to the present invention, which are located on top of each other and are provided with windows and a door.

The living quarters module shown in Fig. 9, the main elements of which are made of plastic material, comprises a set of extruded main beams 1 with a hollow profile, having an elongated rectilinear shape, having a constant cross section and having an appropriate length. These main beams 1 are adapted for end-to-end mounting to form a rectangular lattice structure in the form of a three-dimensional rectangular frame. A plurality of intermediate secondary beams 11 which are adapted to fit between parallel and opposite main beams 1 of the rectangular frame. The module contains a plurality of flat façade elements 3 that can be inserted one on top of the other between two adjacent parallel beams 1, 11, each façade element 3 comprising a rectangular flat slab provided with two bent opposite edges 3A, 3B (Fig. 5), which are subject to engagement with adjacent parallel beams 1, 11.

As shown in FIG. 1, each main beam 1 has a rectangular cross-section, containing on its four sides one or two protrusions 21, parallel to the side and located at a distance from the part of the side located in the direction of its central part, leaving in the direction of each corner of the main beam 1 an opening 22 for accommodating the folded edge 3A, 3B (Fig. 5) of the flat facade element 3 (Fig. 5). Parallel protrusions 21 on each side of the rectangular section of each main beam 1 extend beyond the adjacent side of the rectangular section. In the depicted embodiment, each main beam 1 has on each side two protrusions 21 parallel to and spaced from the side, the two protrusions 21 being separated by a central opening 30.

As shown in FIG. 2, each secondary beam 11 has, on two opposite surfaces, protrusions 23 leaving an opening 24 for receiving the folded edge 3A, 3B (FIG. 5) of the flat façade element 3 (FIG. 5). The secondary beams 11 comprise a square central hollow core 25 and projections 23 extending on either side of this hollow core 25 to define an opening 24 on each side to receive the folded edge of the flat façade element. Each side of the hollow interior of the secondary beam 11 comprises a central ledge defined by two side ledges 23 defining between them two openings 24 to receive the folded edge of the flat façade element. In one embodiment, the two lateral protrusions 23 contain on their outer end an edge that is bent outward and recessed relative to the outer end of the central protrusion by a distance that corresponds to the thickness of the flat facade element. In this embodiment, the outer edges of the hollow interior contain reinforcing profiles.

As shown in FIG. 3, fig. 4A, FIG. 4B, FIG. 6 and FIG. 7, the possibility of mounting the main beams with each other and with the secondary beams is provided by the corner pieces 2A, 2B, 2C, 2D.

For example, as shown in FIG. 3, the corner piece 2A is a transition piece used to connect the main beams to each other using other corner pieces 2C (FIG. 6). The corner piece 2A includes a rod 4 with a square cross section, which is shorter than the main beams and which is adapted to be inserted into the end face of the first main beam. One end of this rod contains a longitudinal groove 5 in the center of each surface of the square rod 4, designed to accommodate a protrusion on the transition element 2C (Fig. 6), made with the possibility of insertion into the hole 5 (Fig. 3) of the second main beam, which can be mounted end to end with the first.

In this example, this corner piece 2A is designed to be vertical and the main beams that are connected to this corner piece 2A are supported by a support ring 6.

In FIG. 4A and FIG. 4B shows the details that guarantee the transition between the main beam and the secondary beam. This transition piece is divided into three parts: the lower part 7, which connects the vertical main beam to the central part 8, which contains two protrusions intended to be inserted into the secondary beam. Finally, another retaining ring 9 is located between the central part 8 and the secondary beam. In addition, the space 10 created in this transition piece 2B allows in particular the possibility of embedding electrical cables or other conduits in addition to a ventilation system that will protrude from the opposite side of the secondary beam in the same place, namely in the space 10 of the other transition piece 2B.

Obviously, the building module shown in FIG. 9, requires holes to be used. Thus, either the entire space occupied by the plate 3 can be left free, for example by using a means to hold the plates 3 adjacent to the hole in place, or alternatively the plate 3 includes removable areas to create holes.

As shown in FIG. 10, two building modules are placed on top of each other. In this example, when the assemblies at the corner of the first building module are compacted to the ground, the boards 3 are resistant to wind loads of up to 182 kg/m ² , the bottom boards 3 are to withstand ground loads of up to 224 kg/m ² , and the top plates 3 of the second module withstand loads on the top of said second module up to 107 kg/m ² .

The upper module of the living space contains four openings that function as windows. Two small windows 18 are created by cutting out two cells on another plate 3'. Two large windows 19 are created, for example, by cutting two cells on two other plates 3 placed on top of each other. The lower living room module has a large opening 20 serving as a door and two small openings 18 serving as windows. The door 20 is created, for example, by cutting two adjacent cells 13 on four other plates placed on top of each other. In this example, even though it is not visible, the common plates 3 between the lower module and the upper module also contain openings between the two modules. In another modification, which is not shown, access to the upper module of the room can be provided by an external staircase.

Thanks to the system according to the present invention, it is possible to combine modules on top of each other, as well as next to each other. The assembly of the corner pieces 2A, 2C (FIGS. 3 and 6) and the main beams 1 allows the accommodation modules to be mounted in six directions, i.e. along the six surfaces of the rectangular living space module, and to do so with a minimum of detail since the corner pieces 2A, 2C provide a transition between the two building modules without other intermediate pieces.

For greater convenience, the plates 3, located at a distance from each other, form a formwork, which makes it possible to introduce an insulating material. It also provides for the embedding of electric cables, and a pipeline, and, secondarily, a tank. The pipeline can be used both for transporting water to a water distribution point located in the specified residential area, and for discharging wastewater from the specified residential area.

The upper part of the living quarters module is always sealed, either by specific placement of boards or, in an example not shown, by placing a tarp onto which a polymerization resin can be applied to make said tarp stiff and waterproof. This design is made using beams and columns. Each post and beam contains holes, in particular those into which screws are inserted, into which tubes with a cross section corresponding to the holes are inserted. These tubes are of sufficient length to constitute a structure that extends beyond the living unit sufficiently to adjust the slope of the roof or roof overhang depending on the geographic location of said living unit. Thus, after this roof structure has been made, one or more tarpaulins, possibly sun tarpaulins, can be placed and stretched so that, for example, a canopy type tent is stretched.

After the tarpaulin has been stretched and shaped, it is necessary to apply a transparent or colored resin, for example, with a brush or spray gun, to the inside or outside of the tarpaulin. After polymerization, a thin, but tough, and resistant, and easily repairable rubber shell is obtained.

In another modification, which is not shown, the upper part of the living quarters module may have a green roof.

In the illustrated example, the building module contains four secondary beams per surface, but in other modifications, each module may contain three or even two secondary beams.

The living room module according to the present invention has the advantage that its installation is easy and fast, and it is so strong that it meets load-bearing standards such as the EN1991 standard.

In all embodiments, the term "plastic material" means any material that can be recycled (HDPE, LDPE, PP, PET, PS, ABS...). Of course, it is quite possible to use non-recycled plastic material.

Whether the plastic material is recycled or not, residential module elements will be manufactured to be durable enough to withstand the stresses of a residential environment. Thus, during their manufacture, the parts may include specific products or techniques that contribute to their rigidity.

Claims (23)

1. A building system for a building module, in particular a dwelling or a garage, the main elements of which are made of plastic material, comprising: a set of extruded main beams (1) with a hollow profile, having an elongated rectilinear shape, having a constant rectangular cross-section and having an appropriate length; moreover, these main beams (1) are adapted for mounting end to end with the formation of a rectangular lattice structure in the form of a three-dimensional rectangular frame; a plurality of intermediate secondary beams (11), which are adapted for installation between parallel and opposite main beams (1) of a rectangular frame, a plurality of flat façade elements (3) made with the possibility of insertion on top of each other between two adjacent parallel beams (1, 11), each façade element (3) comprising a rectangular flat slab provided with two bent opposite edges (3A) intended for engagement with adjacent parallel beams (1, 11), characterized in that each main beam (1) with a rectangular cross section contains on its four sides a protrusion (21) parallel to the side and located at a distance from the part of the side located in the direction of its central part, leaving in the direction of each corner of the main beam (1) an opening (22 ) to accommodate the folded edge (3A) of the flat façade element (3), each secondary beam (11) contains on two opposite surfaces at least one protrusion (23), leaving a hole (24) to accommodate the bent edge (3A) of the flat facade element (3), and while the main beams (1) are mounted using corner pieces (2A, 2C) located between adjacent ends of the main beams (1) in order to be able to combine building modules next to each other and/or one above the other in six directions. 2. The system of claim. 1, characterized in that the parallel ledges on each side of the rectangular section of each main beam extend beyond the adjacent side of the rectangular section. 3. The system according to any one of paragraphs. 1 or 2, characterized in that each main beam contains on each side two protrusions parallel to the side and located at a distance from the part of the side located in the direction of its central part, the two protrusions being separated by a central hole. 4. System according to any one of the preceding claims, characterized in that the secondary beams (11) comprise a central hollow interior, preferably square, and protrusions extending on either side of this hollow interior to define at least one opening on each side (24) to accommodate the folded edge (3B) of the flat façade element (3). 5. The system according to any of the preceding claims, characterized in that each rectangular lattice structure in the form of a three-dimensional rectangular frame constitutes a building module that can be assembled with another module, and the dimensions of each module are from 2.5 to 4.5 m in length sides and in width and from 2.5 to 3.5 m in height. 6. A system according to any one of the preceding claims, characterized in that the flat facade elements (3) contain in their flat plates removable areas for creating openings. 7. System according to any one of the preceding claims, characterized in that the flat façade elements (3) comprise two flat slabs spaced apart to form a formwork. 8. A system according to any one of the preceding claims, characterized in that the building system is made from optionally recycled plastic materials. 9. Assembling a building module of a building constructed from a building system according to any one of paragraphs. 1-8, and the assembly contains: a) at least one building module formed from a three-dimensional rectangular frame of the main beams (1), b) assembly of secondary beams (11) between parallel main beams (1) and c) an assembly of flat façade elements (3) inserted between two parallel beams (1, 11), the folded edges of the façade elements being inserted into said holes (24). 10. Assembly according to claim 9, characterized in that the secondary beams (11) are located vertically, parallel to the vertical main beams (1) and between them, and the facade elements (3) are placed on top of each other between two vertical parallel beams (1, 11 ). 11. Assembly according to claim 9 or 10, characterized in that each beam (1, 11) and optionally the formwork of each facade element (3) is filled with a substance to reinforce their structure. 12. A building, in particular a residential building, such as a house or a garage, containing the assembly according to any one of paragraphs. 9-11.

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