Abstract
A prefabricated modular unit that include a balcony, a living space and part of an interior central corridor of a building. Assembly of a plurality of the prefabricated modular units allows to construct said building.
Claims
1. Prefabricated modular units to be assembled together into a multi-story building, a first one and a second one of the prefabricated modular units comprising: longitudinal beams, a horizontal slab spanning between the longitudinal beams, and walls extending vertically from the horizontal slab, with the horizontal slab extending beyond one of the walls into a slab exceeding portion, wherein the slab exceeding portion of the first prefabricated modular unit being adapted to be coupled to the slab exceeding portion of the second prefabricated modular unit to form an interior corridor.
2. The prefabricated modular units of claim 1, wherein the walls join at room corners and form together a closed living space, the prefabricated modular units comprising a corner structural column about at least one of the room corners.
3. The prefabricated modular units of claim 1, wherein the walls join at room corners and form together a closed living space, the prefabricated modular units comprising at least one intermediary structural column distant from the room corners.
4. The prefabricated modular units of claim 1, further comprising a plurality of perpendicular beams extending transversally that couple the longitudinal beams.
5. The prefabricated modular units of claim 3, further comprising a rod coupling the intermediary structural column to one of the longitudinal beams.
6. The prefabricated modular units of claim 1, further comprising a ventilated duct extending at least partially in one of the longitudinal beams.
7. The prefabricated modular units of claim 1, further comprising a ventilated duct extending in at least a portion of one of the longitudinal beams.
8. The prefabricated modular units of claim 1, wherein the beams of the prefabricated modular units extend longitudinally between two ends, wherein the prefabricated modular units further comprising a securing plate at least one end for securing the prefabricated modular units together.
9. The prefabricated modular units of claim 8, wherein the securing plate comprises a hole for a securing member to extend across.
10. The prefabricated modular units of claim 2, wherein the prefabricated modular units further comprises securing plates ends of the corner structural columns for securing above-story prefabricated modular units on top of the prefabricated modular units.
11. The prefabricated modular units of claim 3, wherein the prefabricated modular units further comprises securing plates ends of the intermediary structural columns for securing above-story prefabricated modular units on top of the prefabricated modular units.
12. The prefabricated modular unit of claim 1, further comprising a cast interior dividing wall with a cast door frame and a finishing molding.
13. The prefabricated modular units of claim 1, further comprising vertical a plumbing shaft and an extruded insulation blanket cast together.
14. A building comprising the prefabricated modular units of claim 8 assembled together, the building comprising securing pins extending through the securing plate, the securing pins securing the prefabricated modular units to each other.
15. A building comprising the prefabricated modular units and the above-story prefabricated modular units of claim 10 assembled together, the building comprising securing pins extending through the securing plate, the securing pins securing the above-story prefabricated modular units to the prefabricated modular units.
16. A building comprising the prefabricated modular units and the above-story prefabricated modular units of claim 11 assembled together, the building comprising securing pins extending through the securing plate, the securing pins securing the above-story prefabricated modular units to the prefabricated modular units.
17. A building comprising the prefabricated modular units of claim 8 and an adjacent prefabricated modular unit similar to the prefabricated modular units, one of the longitudinal beams of the adjacent modular unit extending parallel to and side-by-side with one of the longitudinal beams of a first one of the prefabricated modular units, the building further comprising a bridge plate extending over adjacent securing plates of the first prefabricated modular unit and the adjacent modular unit , the bridge plate comprising holes aligned with the holes of the securing plates for securing pins to extend therethrough, wherein the bridge plate coupled to one of the securing plates of the first modular unit and to one of the securing plates of the adjacent modular unit is securing them together.
18. The building of claim 17, wherein the bridge plate comprises a protrusion comprising side walls for abutting the first prefabricated modular unit and the adjacent modular unit.
19. A building comprising the prefabricated modular units of claim 8, further comprising a securing pin comprising a first member comprising a threaded bore, and a second member comprising a threaded shaft for screwing in the threaded bore.
20. The building of claim 17, wherein first member and second member of the securing pin comprise an abutting face facing each other, the abutting faces having a length and a width, with the length being greater than the width.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Further features and advantages of the present disclosure will become apparent from the following detailed description, taken in combination with the appended drawings, in which:
[0031] FIG. 1 is a diagrammatic perspective view of construction of a multi-story building in an incomplete stage according to a system embodying the principles of the present invention employing prefabricated modular units made of reinforced concrete. In the depicted embodiment, the modular units include a balcony, a living space and part of the interior central corridor;
[0032] FIG. 2 is an isometric view of an exemplary prefabricated modular unit in accordance with an embodiment;
[0033] FIG. 3 a side sectional view of an exemplary portion of the multi-story building of FIG. 1;
[0034] FIG. 4 is a front sectional view of an exemplary portion of the multi-story building of FIG. 1;
[0035] FIG. 5 is a plan view of the lower level parking; of the multi-story building of FIG. 1;
[0036] FIG. 6 is a side view of a ground and second level multi-story building prefabricated modular unit with an overhanging portion over the lower level parking, said overhanging portion being structurally supported by two longitudinal cantilever beams, with the prefabricated modular units of other levels having an overhanging portion over the lower prefabricated modular units;
[0037] FIG. 7 is a side view of a prefabricated modular unit with two overhanging portions; one over the lower level parking and one over the fa?ade of the building, with the overhanging over the fa?ade and over the lower level parking being supported by a cantilever beams;
[0038] FIG. 8 is a front sectional view of the structural member being used for attaching the prefabricated modular unit together;
[0039] FIG. 9 is a front sectional view of an alternate steel supporting beam;
[0040] FIG. 10 Illustrate a plan view of a typical floor of a building being built with several prefabricated modular units in accordance with an embodiment;
[0041] FIG. 11 is a plan view of an exemplary dwelling built with two prefabricated modular units;
[0042] FIG. 12 is a cross sectional detail view of an exterior wall and of a balcony;
[0043] FIG. 13 is a front sectional view of a prefabricated modular unit being partially used for an emergency staircase;
[0044] FIG. 14 is a plan view of a prefabricated modular unit being partially used for an emergency staircase;
[0045] FIG. 15 is a front sectional view of a prefabricated modular unit being partially used for an elevator shaft;
[0046] FIG. 16 is a plan view of a prefabricated modular unit being partially used for an elevator shaft;
[0047] FIG. 17 is a front sectional view of prefabricated roof slab; and
[0048] FIG. 18 is a sectional elevation view of the interior portion of an exterior wall;
[0049] FIG. 19 is a sectional elevation view of an interior dividing wall;
[0050] FIG. 20 is a sectional view of a cast door frame;
[0051] FIG. 21 is a plan sectional view of an exterior wall of a prefabricated modular unit;
[0052] FIG. 22 is a plan view of a plumbing vertical shaft and a casting technique using extruded insulation;
[0053] FIG. 23 is an isometric view of an exemplary prefabricated modular unit showing the height (8) anchor steel plate being used to transport and hoist the prefabricated modular units with standard shipping container trailers and lifting cranes;
[0054] FIG. 24 is a partial view of a prefabricated modular unit showing tow (2) anchor steel plates welded or screwed to the structural column steel rebars;
[0055] FIG. 25 is an elevation cut view of a twist lock stacking pin being made of 2 parts screwed one into another;
[0056] FIG. 26 is a top view of a twist lock stacking pin similar to the stacking being used in the shipping container industry;
[0057] FIG. 27 is a partial view of a prefabricated modular unit showing an anchor steel plate with an oval opening to be used with twist lock stacking pins;
[0058] FIG. 28 is a top view of a bridge plate to secure horizontally two prefabricated modular units;
[0059] FIG. 29 is a side view of a bridge plate assembly with two (2) twist lock stacking pins; and
[0060] FIG. 30 is a partial view of two (2) prefabricated modular units being attached horizontally with a bridge plate and two (2) twist lock stacking pins.
[0061] It will be noted that throughout the appended drawings, like features are identified by like reference numerals.
DETAILED DESCRIPTION
[0062] The realizations will now be described more fully hereinafter with reference to the accompanying figures, in which realizations are illustrated. The foregoing may, however, be embodied in many different forms and should not be construed as limited to the illustrated realizations set forth herein.
[0063] As will be realized, the subject matter disclosed and claimed is capable of modifications in various respects, all without departing from the scope of the description. Accordingly, the drawings and the description are to be regarded as illustrative in nature.
[0064] With respect to the present description, references to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. Thus, the term or should generally be understood to mean and/or and so forth.
[0065] Recitation of ranges of values and of values herein or on the drawings are not intended to be limiting, referring instead individually to any and all values falling within the range, unless otherwise indicated herein, and each separate value within such a range is incorporated into the specification as if it were individually recited herein. The words about, approximately, or the like, when accompanying a numerical value, are to be construed as indicating a deviation as would be appreciated by one of ordinary skill in the art to operate satisfactorily for an intended purpose. Ranges of values and/or numeric values are provided herein as examples only, and do not constitute a limitation on the scope of the described realizations. The use of any and all examples, or exemplary language e.g., such as, or the like provided herein, is intended merely to better illuminate the exemplary realizations and does not pose a limitation on the scope of the realizations. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the realizations.
[0066] In the following description, it is understood that terms such as first, second, top, bottom, above, below, and the like, are words of convenience and are not to be construed as limiting terms.
[0067] The terms top, up, upper, bottom, lower, down, vertical, horizontal, interior and exterior and the like are intended to be construed in their normal meaning in relation with normal installation of the product.
[0068] In realizations, there are disclosed prefabricated modular units and assembly of prefabricated modular units.
[0069] It will be noted that throughout the appended drawings, like features are identified by like reference numerals.
[0070] Referring now to the drawings, description is provided of modular units and a of building constructed with modular units.
[0071] FIG. 1 is an isometric view of several level of modular units of an incomplete building. Prefabricated modular units, e.g., prefabricated modular units 1, 2, 3, are set in place by means of a crane (not shown) at the building site, over a lower level parking 4 and lower level columns 17, 19. Prefabricated modular units e.g., prefabricated modular units 1, 2, 3, have a floor slab 5 cast to two longitudinal beams 6, 7, an exterior wall 8, interior dividing walls 10 with no ceiling for weight saving consideration. All prefabricated modular units, e.g., prefabricated modular units 1, 2, 3, are cast with a balcony 22 supported by two longitudinal beams 6 and 7. Prefabricated modular units, e.g., prefabricated modular units 1, 2, 3, include part of a central corridor 11. Prefabricated modular unit, e.g., prefabricated modular unit 2, may exceed the adjacent module 1 to improve aesthetic of the building or to comply with local bylaws. Corner modular units, e.g., prefabricated modular units 2 and 3, may not include part of a central corridor 11.
[0072] FIG. 2 is an isometric perspective view of an exemplary modular unit 1 used in the present invention which forms a basic structural component of a modular building according to the present invention and referring to FIG. 1. Each of the embodiments are cast at the factory from concrete as an independent rigid prefabricated modular unit. Each one is basically rectangular in shape, comprising a floor slab 5 cast on two longitudinal beams 6, 7, exterior walls 8, interior dividing walls 10, four structural columns 15, 18, a balcony 22, and a portion of a central corridor 11, but without a ceiling. Several perpendicular beams 54 are attached to the longitudinal beams 6, 7.
[0073] FIG. 3 is a side sectional view of an exemplary portion of the multi-story building of FIG. 1 being built over a lower level parking 4 comprising parking spaces 13 and a circulation alley 14. Structural columns 15 of the prefabricated modular units, e.g., prefabricated modular units 20 and 21, sit on top of foundation wall 16 of the building or on lower level structural columns 17, 19. Structural column 18 of the prefabricated modular units, e.g., prefabricated modular units 20 and 21, sits on top of lower level structural columns 19, 17. It is understood that parking spaces 13 and circulation alley 14 may be located differently from the drawing without departing from the scope of the description. Prefabricated modular units, e.g., prefabricated modular units 20, 21, are cast with a balcony 22. Prefabricated modular unit, e.g., prefabricated modular units 20, 21, have an overhanging portion 23 over the circulation alley 14. Prefabricated modular units, e.g., prefabricated modular units 20, are cast with part of central corridors 24, 25, 26, 27
[0074] Prefabricated modular unit 52, 53 have an overhanging portion 23 over the lower level prefabricated modular unit(s) e.g., lower level prefabricated modular units 20, 21.
[0075] FIG. 4 is a front sectional view of an exemplary portion of the multi-story building of FIG. 1 being built over a lower level parking 4. Prefabricated modular unit 28 is used as a loft. By combining two prefabricated modular units, e.g., prefabricated modular unit 29, the living dwelling becomes a one-bedroom apartment. By combining three prefabricated modular units, e.g., prefabricated modular unit 30, the dwelling becomes a two-bedroom apartment. By combining four prefabricated modular units, e.g., prefabricated modular unit 31, the dwelling becomes a three-bedroom apartment. Prefabricated modular unit 32 is being used as an emergency staircase with cast or steel stairs. Prefabricated modular unit 33 is being used as an elevator shaft.
[0076] FIG. 5 is a plan view of the lower level parking 4 of FIG. 1, comprising parking spaces 13, a circulation alley 14, foundation walls 16, structural columns 17 and 19, lower level emergency staircases 34, and a lower level elevator shaft 35. Walls of the emergency staircases 34 and of the elevator shaft 35 are used as shear walls and are made of reinforced concrete to withstand earthquakes.
[0077] FIG. 6 is a side view of a ground-level prefabricated modular unit 21 with section 36 of the prefabricated modular unit 21 overhanging parking spaces 13 and circulation alley 14. The prefabricated modular units 53 of other levels have a section 55 of the prefabricated modular unit 53 and central corridor 26 overhanging the lower level modular unit 21. Prefabricated modular units 21 have a floor slab 5 cast with the two longitudinal concrete beams 6, 7 with one shown on the side view. Longitudinal beam 7 extends out of the prefabricated modular unit to support the balcony 22. The balcony 22 is cast at the factory and assembled with railings 37 and an air conditioning condenser 38. To reduce the size of the longitudinal beams 6, 7, rods 39 are attached to the beam 7 and hang to the column 18, with one shown on the side view, to lower the section of the cantilever portion of the longitudinal beams 6, 7. Ventilation duct 42 is being inserted in the beam 6, 7. A ventilation outlet 43 is located at the outside extremity of the beam 6, 7. Perpendicular beams 54 are attached to the longitudinal beams 6, 7.
[0078] FIG. 7 is a side view of a prefabricated modular units 21, 53 with an overhanging fa?ade 81 of the building, overhang over the fa?ade 81 being supported by two longitudinal beams 6, 7.
[0079] FIG. 8 is a front sectional view of a plurality of prefabricated modular units 1 being joint by a multitude of bridge plates 41. Ventilation duct 42 are shown in the center of concrete beams 6, 7
[0080] FIG. 9 is a front sectional view of a prefabricated modular unit 1 being built with a concrete slab 5 supported by steel beams 44, 45. Fireproofing of the steel beams 44, 45 is realized with a gypsum box 46.
[0081] FIG. 10 is a plan view of a typical building built with prefabricated modular units 1, 3. Horizontal interlocking of the individual prefabricated modular units 1, 3 is realized with the structural floor of the central corridor. The interlocking of prefabricated modular units, e.g., prefabricated modular units 1, 3, is realized with a plurality of structural members 47, 48.
[0082] FIG. 11 is a plan view of an exemplary one-room dwelling built with two prefabricated modular units, e.g., prefabricated modular units 50, 51.
[0083] Prefabricated modular unit 50 contains all mechanical equipment, plumbing fixtures and electrical distribution systems which service part of the dwelling. The prefabricated modular unit 51 contains a fully furnished kitchen including cabinets, sink, dishwasher, disposal, electric range, ventilation hood, dining and living room, air conditioning 59, condenser 38, balcony 22, railings, insulated exterior wall, and pre-hung doors 57.
[0084] The second prefabricated modular unit 50 includes a room, a hallway for internal circulation, a bathroom consisting of a tub, a shower, a toilet, a vanity, a linen closet, a facility comprising an electric clothes dryer, a washing machine, a heat exchanger 56 for venting the bathroom, floor finishing, tiles, and a pre-hung door. Prefabricated modular unit comprising of a balcony 22, railing, insulated exterior wall 1, prewired interior dividing wall 10, pre-hung doors 57 and windows 58, hot water tank 49. prefabricated modular unit exterior wall is completed with insulation, vapor and wind barrier, waterproofing of door and windows opening.
[0085] A third prefabricated modular unit (not shown) is used to build a two-bedroom dwelling and includes a room, a hallway for internal circulation, a bathroom consisting of a tub, a shower, a toilet, a vanity, a linen closet, a fan 56 for venting the bathroom, floor finishing, tiles, and a pre-hung door. Prefabricated modular unit comprising of a balcony 22, railing, insulated exterior wall, prewired interior dividing wall 10, pre-hung doors 57 and windows 58. prefabricated modular unit exterior wall is completed with insulation, vapor and wind barrier, waterproofing of door and windows opening.
[0086] A fourth prefabricated modular unit (not shown) is used to build a three-bedroom dwelling and includes a room, a hallway for internal circulation, a bathroom consisting of a tub, a shower, a toilet, a vanity, a linen closet, a fan 56 for venting the bathroom, floor finishing, tiles, and a pre-hung door. Prefabricated modular unit comprising of a balcony 22, railing, insulated exterior wall, prewired interior dividing wall 10, pre-hung doors 57 and windows 58. Exterior wall of the prefabricated modular unit is completed with insulation, vapor and wind barrier, waterproofing of door and windows opening.
[0087] FIG. 12 is a cross sectional detailed view of an exterior wall and of a balcony 22. Indoor portion 60 of the exterior wall 8 is pre-wired and cast in concrete. Wind barrier, insulation 61 and vapor barrier are being attached to the indoor portion 60 of the exterior wall 8. The wind barrier, insulation and vapor barrier runs through an opening 62 in the slab and in longitudinal concrete beams 6, 7. The opening 62 in the slab is separating the cold outdoor from the heated portion of the dwelling. It acts as a thermal barrier. Exterior finishing consists of wood, metal siding, tiles or brick that sit on a perpendicular concrete beam 54 spanning from the two longitudinal beams 6,7. Ventilation outlet 43 at the extremity of the beam is shown with plenum 63, back-draft damper, and duct 42.
[0088] FIG. 13 is a front sectional view of a prefabricated modular unit 32 being partially used for an emergency staircase. Access door 64 to the emergency staircase is fire-rated. The perimeter walls 65 of the emergency staircase are used as shear walls made of reinforced concrete. The stairs 66 are made of steel or reinforced concrete. Perpendicular beams 54 span from the longitudinal beams 6, 7.
[0089] FIG. 14 is a plan view of a prefabricated modular unit 32 being partially used for an emergency staircase comprising shear walls 65, central corridor walls 67, fire-rated doors 64 and stairs 66. Unused portions 68 of the prefabricated modular unit 32 and balcony 22 are used by an adjacent dwelling.
[0090] FIG. 15 is a front sectional view of a prefabricated modular unit 33 being partially used for an elevator shaft 69. The perimeter walls 70 of the elevator shaft 69 are used as shear walls made of reinforced concrete.
[0091] FIG. 16 is a plan view of a prefabricated modular unit 33 being partially used for an elevator shaft 69 comprising shear walls 70, central corridor 11. Unused portions 93 of the prefabricated modular unit 33 and balcony 22 are used by an adjacent dwelling.
[0092] FIG. 17 is a front sectional view of the prefabricated roof slab 71. Prefabricated roof slab 71 is completed with two longitudinal concrete beams 6,7, supporting the roof slab 71. Top of roof slab 71 has a 2-dimentionnal slope 72 to guide the rain water toward the roof drain (not shown). Longitudinal concrete beams are completed with ventilation duct 42 for venting the last floor dwelling unit, the prefabricated roof slab 71 being joined by bridge plates 41.
[0093] FIG. 18 is a sectional elevation view of an interior part 60 of an exterior wall. All interior walls and the exterior walls of the prefabricated modular unit are cast at the factory. Door frames 74, latch holes 78, hinges depression 79 and perimeter moldings 73 on one side of the door frame are cast simultaneously with the casting of the wall. Bottom molding 75 on one side of the wall is cast simultaneously with the casting of the wall 60.
[0094] Window frames 76, interior finish and window perimeter molding 77 of the window frame are cast simultaneously with the casting of the interior parts of the perimeter wall 60.
[0095] FIG. 19 is a sectional elevation of an internal dividing wall 10. All dividing walls 10 of the prefabricated modular unit are cast at the factory. Door frames 74, latch holes 78, hinges depression 79 and perimeter molding 73 on both sides of the said door frame are cast simultaneously with the casting of the wall. Bottom moldings 75 on each side of the wall are cast simultaneously with the casting of the dividing wall 10.
[0096] FIG. 20 is a sectional view of a cast door frame 74, latch holes 78, hinges depression 79, perimeter molding 73 and door stopper 80.
[0097] FIG. 21 is an interior sectional view of an exterior wall of a prefabricated modular unit 1. Perpendicular beam 54 span from the longitudinal beams 6, 7.
[0098] FIG. 22 is a plan view of a plumbing vertical shaft 82. Plumbing pipes 9 are placed into an extruded insulation blanket 40. The assembly of the insulation blanket 40 and pipes 9 are inserted into the mold and concrete 85 is poured around the pipe/insulation assembly.
[0099] FIG. 23 is an isometric view of an exemplary prefabricated modular unit 1 showing the top anchor steel plate 86 being used to lift the prefabricated modular unit. Lower anchor steel plate 87 are used to transport the prefabricated modular units.
[0100] FIG. 24 is a partial view of a prefabricated modular unit 1 showing the top anchor steel plate 86 and the lower anchor steel plate 87 being welded or screwed to the structural columns 18 and steel rebars 88.
[0101] FIG. 25 is an elevation cut view of a twist lock stacking pin 83 being made of a top pin 89 and a lower pin 92 comprising a threaded end 94.
[0102] FIG. 26 is a top view of a twist lock stacking pin 83. A difference between the twist lock pin 83 and a pin currently used with containers is that the twist lock stacking pin 83 is made of 2 parts instead of being a one-piece cast stacking pin.
[0103] FIG. 27 is a partial view of a prefabricated modular unit 1 showing a top anchor steel plate 86 with an oval opening 84 to be used with a twist lock stacking pin 83.
[0104] FIG. 28 is a top view of a bridge plate 41 to secure horizontally two (2) prefabricated modular units. Bridge plate 41 has two (2) openings 90, e.g., oval openings, to be used with twist lock stacking pins 83.
[0105] FIG. 29 is a side view of a bridge plate 41 assembly with two (2) twist lock stacking pins 83. Locking plate 91 is used to limit the rotation of the bridge plate 41.
[0106] FIG. 30 is a partial view of two (2) adjacent prefabricated modular units 1 being attached horizontally with a bridge plate 41, a top anchor steel plate 86 being attached to the bridge plate 41 using and two (2) twist lock stacking pins 83 mounted to the top anchor steel places 86. Depicted on the left is the twist lock pin 83 depicted is an insertion position, and on the right is depicted the twist lock pin 83 being shown in a locking position with an abutting interface 12 preventing the twist lock pin 83 to exit,
[0107] While preferred embodiments have been described above and illustrated in the accompanying drawings, it will be evident to those skilled in the art that modifications may be made without departing from this disclosure. Such modifications are considered as possible variants comprised in the scope of the disclosure.
