CONSTRUCTION SYSTEM FOR A BUILDING MODULE

Abstract

The present invention concerns a construction system for a building module, whose main elements are made of plastic material, providing a robust construction in an easy and quick manner. The system includes a set of main beams (1) adapted to be assembled end-to-end to form an open structure in the shape of a 3-dimensional rectangular frame. The system further includes secondary beams (11), adapted to be assembled between parallel and opposite main beams, and flat facade elements (3) insertable against each other between two adjacent parallel beams. Each facade element (3) includes a rectangular flat plate provided with two folded opposite edges (3A) intended to be hooked with adjacent parallel beams. Each main beam has a rectangular cross-section including, on the four sides thereof, a projection (21) parallel to the side and spaced therefrom leaving an opening to receive a folded edge of a flat facade element. Each secondary beam (11) includes, on two opposite faces, at least one projection leaving an opening to receive a folded edge of a flat facade element (3).

Claims

1. A construction system for a building module, in particular a dwelling or a garage, whose main elements are made of a plastic material, including: A set of extruded, hollow profile main beams (1), of an elongated rectilinear shape, of a uniform rectangular cross-section and of adequate length; These main beams (1) being adapted to be assembled end-to-end to form a rectangular open structure in the shape of a 3-dimensional rectangular frame; A plurality of intermediate secondary beams (11), which are adapted to be assembled between parallel and opposite main beams (1) of a rectangular frame, A plurality of flat facade elements (3) insertable against each other between two adjacent parallel beams (1, 11), each facade element (3) including a rectangular flat plate provided with two folded opposite edges (3A) intended to be hooked with adjacent parallel beams (1,11), Characterized in that Each rectangular cross-section main beam (1) includes, on the four sides thereof, a projection (21) parallel to a side and spaced from a portion of the side disposed towards the central portion thereof, leaving towards each corner of the main beam (1), an opening (22) to receive a folded edge (3A) of a flat facade element (3), Each secondary beam (11) includes at least, on two opposite faces, one projection (23) leaving an opening (24) to receive a folded edge (3A) of a flat facade element (3), And in that the main beams (1) are assembled by means of corner parts (2A, 2C) disposed between the adjacent ends of the main beams (1) in order to be able to combine construction modules next to each other and/or above each other in six directions.

2. The system according to claim 1, wherein the parallel projections 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 claim 1, wherein each main beam includes on each side, two projections parallel to the side and spaced from a portion of the side disposed towards the central portion thereof, the two projections being divided by a central opening.

4. The system according to claim 1, wherein the secondary beams (11) include a central hollow core, preferably square, and projections extending on either side of this hollow core, to define on each side, at least one opening (24) for receiving the folded edge (3B) of a flat facade element (3).

5. The system according to claim 1, wherein each rectangular open structure in the shape of a 3-dimensional rectangular frame, constitutes a construction module which can be assembled with another module, each module measuring between 2.5 m and 4.5 m in side length and in width and between 2.5 m and 3.5 m in height.

6. The system according to claim 1, wherein the flat facade elements (3) include, in their flat plates, removable areas to create openings.

7. The system according to claim 1, wherein the flat facade elements (3) include two flat plates spaced from each other to form a formwork.

8. The system according to claim 1, wherein the construction system is made from optionally-recycled plastic materials.

9. An extrusion method for manufacturing a system according to claim 1, under a carbon dioxide atmosphere in a subcritical cycle or by addition of a hardening product.

10. An assembly of a building construction module constructed from a construction system according to claim 1, the assembly including: a. At least one construction module formed of a three-dimensional rectangular frame of main beams (1), b. An assembly of secondary beams (11) between parallel main beams (1), and c. An assembly of flat facade elements (3) inserted between two parallel beams (1, 11), the folded edges of the facade elements being inserted into said openings (24).

11. The assembly according to claim 10, wherein secondary beams (11) are disposed vertically, parallel to and between vertical main beams (1), and the facade elements (3) are placed on top of each other between two vertical parallel beams (1, 11).

12. The assembly according to claim 10 or 11, wherein each beam (1, 11), and optionally the formwork of each facade element (3), is filled with a substance for reinforcing the structure thereof.

13. A building, in particular a residential building, for instance a house or a garage, including an assembly according to claim 1.

Description

[0034] The features of the invention will appear more clearly on reading the following non-limiting description of several embodiments given only by way of example, with reference to the schematic figures, in which:

[0035] FIG. 1 represents a partial perspective view of a main beam;

[0036] FIG. 2 represents a partial perspective view of a secondary beam;

[0037] FIG. 3 represents a perspective view of part for joining main beams;

[0038] FIG. 4A represents a perspective view of a non-assembled junction part between a main beam and a secondary beam;

[0039] FIG. 4B represents a perspective view of the assembled FIG. 4A;

[0040] FIG. 5 represents a perspective view of a facade element;

[0041] FIG. 6 represents a perspective view of a part for joining a main beam, for example, a horizontal beam, and another part for joining a main beam, for example, a vertical beam;

[0042] FIG. 7 represents a perspective view of a finishing element which can be arranged on a part for joining main beams;

[0043] FIG. 8 represents a partial perspective view of the assembly of a construction module according to the present invention;

[0044] FIG. 9 represents a perspective view of a construction module without the upper portion; and

[0045] FIG. 10 represents two dwelling modules according to the present invention which are superimposed on top of each other and provided with windows and a door.

[0046] A module of a dwelling as illustrated in FIG. 9, whose main elements are made of plastic material include a set of extruded, hollow profile main beams 1, of an elongated rectilinear shape, of a uniform cross-section and of an adequate length. These main beams 1 are adapted to be assembled end-to-end to form a rectangular open structure in the shape of a 3-dimensional rectangular frame. A plurality of intermediate secondary beams 11, which are adapted to be assembled between parallel and opposite main beams 1 of a rectangular frame. The module includes a plurality of flat facade elements 3 insertable against each other between two adjacent parallel beams 1, 11, each facade element 3 including a rectangular flat plate provided with two folded opposite edges 3A, 3B (FIG. 5) which are to be hooked with adjacent parallel beams 1, 11.

[0047] As illustrated in FIG. 1, each main beam 1 has a rectangular cross-section including, on the four sides thereof, one or two projections 21 parallel to the side and spaced from a side portion disposed towards the central portion thereof, leaving towards each corner of the main beam 1, an opening 22 to receive a folded edge 3A, 3B (FIG. 5) of a flat facade element 3 (FIG. 5). The parallel projections 21 on each side of the rectangular section of each main beam 1, extend beyond the adjacent side of the rectangular section. In the illustrated embodiment, each main beam 1 includes, on each side, two projections 21 parallel to the side and spaced therefrom, the two projections 21 being divided by a central opening 30.

[0048] As illustrated in FIG. 2, each secondary beam 11 includes, on two opposite faces, projections 23 leaving an opening 24 to receive a folded edge 3A, 3B (FIG. 5) of a flat facade element 3 (FIG. 5). The secondary beams 11 include a square central hollow core 25 and projections 23 extending on either side of this hollow core 25 to define on each side, an opening 24 to receive the folded edge of a flat facade element. Each side of the hollow core of a secondary beam 11 includes a central projection bordered by two lateral projections 23 defining therebetween, two openings 24 for receiving the folded edge of a flat facade element. In one embodiment, the two lateral projections 23 include at their outer end, an edge which is outwardly-folded and recessed relative to the outer end of the central projection, by a distance which corresponds to the thickness of a flat facade element. In this embodiment, the other edges of the hollow core include reinforcing profiles.

[0049] As illustrated in FIGS. 3, 4A, 4B, 6 and 7, corner parts 2A, 2B, 2C, 2D allow, assembling the main beams to each other and to secondary beams.

[0050] For example, as illustrated in FIG. 3, the corner part 2A is a junction part used to connect the main beams to each other by means of the other corner parts 2C (FIG. 6). The corner part 2A includes a square cross-section rod 4, shorter than the main beams, and insertable into the end of a first main beam. One end of this rod includes a longitudinal groove 5 in the center of each face of the square rod 4 intended to receive a projection on a junction element 2C (FIG. 6) insertable into the opening 5 (FIG. 3) of a second main beam which can be assembled end-to-end with the first.

[0051] In this example, this corner part 2A is intended to be positioned vertically and the main beams, which are connected to this corner part 2A, rest on a support ring 6.

[0052] FIGS. 4A and 4B illustrate parts ensuring the junction between a main beam and a secondary beam. This junction part is broken down into three portions, a lower portion 7 which connects a vertical main beam to a central portion 8 that includes two projections intended to be inserted into a secondary beam. Finally, another holding ring 9 is arranged between the central portion 8 and the secondary beam. Besides, the space 10 created in this junction part 2B allows in particular electrical cables or other pipes to be integrated, in addition to an aeration system which will protrude from the opposite side of the secondary beam, in the same place, namely in the space 10 of another junction part 2B.

[0053] It is obvious that the construction module as illustrated in FIG. 9 requires openings in order to be used. Thus, either it is possible to leave free the total space occupied by a plate 3, for example using means for holding in position the plates 3, adjacent to the opening, or alternatively, the plate 3 includes removable areas to create openings.

[0054] As illustrated in FIG. 10, two construction modules are superimposed on top of each other. In this example, when the assembly elements at the corner of the first construction module are sealed to the ground, the plates 3 resist wind up to 182 kg/m.sup.2, the lower plates 3 support ground loads up to 224 kg/m.sup.2 and the upper plates 3 of the second module support loads on the upper part of said second module up to 107 kg/m.sup.2.

[0055] The upper dwelling module includes four openings that act as windows. Two small windows 18 are created by cutting two compartments on another plate 3. Two large windows 19 are for example created by cutting out two compartments on two other plates 3 mounted on top of each other. The lower dwelling module has a large opening 20 serving as a door and two small openings 18 serving as windows. The door 20 is for example created by cutting two adjacent compartments 13 on four other plates mounted on top of each other. In this example, even if not visible, the common plates 3 between the bottom module and the upper module also include openings between the two modules. In another version which is not illustrated, an outer staircase can provide access to the upper housing module.

[0056] Thanks to the system of the present invention, it is possible to combine modules on top of each other but also next to each other. The assembly of the corner parts 2A, 2C (FIG. 3 and FIG. 6) and of the main beams 1 allow dwelling modules to be assembled in six directions, i.e. along the six faces of a rectangular dwelling module, and this with a minimum of parts since the corner parts 2A, 2C provide a junction between two construction modules without other intermediate parts.

[0057] For more comfort, the plates 3 spaced from each other form a formwork allowing an insulating material to be incorporated. It is also envisaged to incorporate electrical cables and piping and secondarily a tank thereto. The piping can be used both for transporting water to a water point disposed in said dwelling and for discharging waste-water outside said dwelling.

[0058] The upper portion of the module of a dwelling is always sealed either by a particular mounting of the plates or, in an example which is not illustrated, by the positioning of a tarpaulin on which a polymerizing resin can be applied making said tarpaulin rigid and waterproof. Such a structure is made using beams and columns. Each post and beam includes holes, in particular those in which screws are inserted, in which tubes of a cross-section corresponding to the holes are inserted. These tubes are long enough to constitute a structure which extends beyond the dwelling module in a manner sufficient to adjust the slope of a roof or a roof overhang depending on the geographic location of said dwelling module. Thus, once this structure for the roof has been made, one or more tarpaulin(s), possibly solar, can be disposed and stretched as, for example, a marquee-type tent is stretched.

[0059] Once the tarpaulin is stretched and shaped, the application of a transparent or colored resin, for example with a brush or a spray gun, should be carried out on the inner or outer portion of the tarpaulin. After polymerization, a thin but rigid and resistant and easily repairable resin shell is then obtained.

[0060] In another version that is not illustrated, the upper portion of the dwelling module can have a green roof.

[0061] In the illustrated example, the construction module includes four secondary beams per face, but in other variants, each module may include three or even two secondary beams.

[0062] A dwelling module according to the present invention has the advantage of being easy and quick to assemble and it is so robust that it meets the standards for load-bearing structures such as the standard EN1991. In all the embodiments, the term plastic material means any material which can be recycled (HDPE, LDPE, PP, PET, PS, ABS . . . ). Of course, it is entirely possible to use non-recycled plastic material.

[0063] Regardless of whether the plastic material is recycled or not, the elements of the dwelling modules will be manufactured so as to be sufficiently resistant to support loads specific to dwellings. Thus, during their manufacture, the parts may include particular products or techniques promoting their rigidity.