PREFABRICATED CONSTRUCTION SYSTEM AND METHOD WITH THREE-DIMENSIONAL STRUCTURAL NODES

Abstract

The present invention relates to a prefabricated construction system and method, for erecting constructions by means of the assembly of prefabricated structural elements obtained by cutting flat materials, forming structural nodes by means of coupling at least a first coupling configuration formed by first slots made in a plurality of parallel boards forming a first structural element with at least a second coupling configuration formed by second slots made in a plurality of parallel boards forming a second structural element, providing a structural core in the form of an array having interstitial openings going through it which allow the coupling of third and fourth coupling configurations of third and fourth structural elements.

Claims

1. A prefabricated construction system with three-dimensional structural nodes comprising: a first elongated structural element (1), arranged with the longer edges thereof being horizontal or with an inclination of ±45° with respect to the horizontal, and said first structural element (1) being provided with at least a first coupling configuration in at least a lower half or an upper half of said first structural element; a second elongated structural element (2), arranged with the longer edges thereof being horizontal or with an inclination of ±45° with respect to the horizontal, and said second structural element (2) being provided with at least a second coupling configuration in at least a lower half or an upper half of said second structural element opposite the half where the first coupling configuration is housed, said second coupling configuration in the assembly position being coupled to said first coupling configuration of the first structural element; the first and second structural elements being non-parallel, and the coupling of the respective coupling configurations of said first, second and a third structural elements forming a resistant structural node; and the structural elements in the mounting position forming a frame on which a vertical and an horizontal enclosures are fixed; wherein the first and second structural elements (1, 2) are each formed by at least a plurality of parallel and spaced boards (7) and/or groups of boards (5); each board (7) is flat and elongated and has at least two parallel front faces (6), which are those having the larger surface, two head faces at the ends thereof farthest from one another, and two side faces (8); each group of boards (5) is a set of boards (7) arranged with the front faces (6) thereof being adjacent, matching and in contact; the boards (7) and/or groups of boards (5) forming the first and second structural elements (1 and 2) are arranged in the assembly position with the front faces (6) thereof in the vertical position arranged parallel to, facing and spaced from one another; the first coupling configuration (10) has a plurality of first straight slots (11), defining first projections (12), said first slots (11) being made from a side face of the boards of the first structural element (1) to at least a fifth of the width of the front faces of said first structural element; the second coupling configuration (20) has a plurality of second straight slots (21), defining second projections (22), said second slots being complementary to the first slots and being made from a side face of the boards of the second structural element (2) to at least a fifth of the width of the front faces of the second structural element; wherein the coupling of the first structural element (1) and the second structural element (2) forms an array leaving free interstitial openings (50) vertically going through the structural node, forming the attachment of the first and second structural elements (1 and 2); and wherein the system further includes: a third structural element (3) arranged in the mounting position with the longer edges thereof being vertical, said third structural element (3) being formed by at least a plurality of parallel boards (7) and/or groups of boards (5) arranged in the assembly position with the front faces (6) thereof in the vertical position arranged parallel to, facing and spaced from one another; and in that: the third structural element (3) is provided with at least a third coupling configuration (30), which has a plurality of third straight slots (31), defining third projections (32), said third slots (31) being made from the head of the third structural element (3) to a depth of at least a fifth of the width of the front faces (6) of the first structural element (1), said third projections (32) in the mounting position being inserted into said interstitial openings (50) of the structural node, formed by the coupling of the first and second structural elements (1 and 2).

2. The construction system according to claim 1, wherein it includes at least one of the following features: the number of first slots (11) of the first coupling configuration (10) is equal to the number of boards (7) and/or groups of boards (5) of the second structural element (2); the number of second slots (21) of the second coupling configuration (20) is equal to the number of boards (7) and/or groups of boards (5) of the first structural element (1); the width of the first slots (11) is equal to the thickness of the boards (7) and/or groups of boards (5) of the second structural element (2); the width of the second slots (21) is equal to the thickness of the boards (7) and/or groups of boards (5) of the first structural element (1); the first projections (12) have a width equal to the between the boards (7) and/or the groups of boards (5) of the second structural element (2); the second projections (22) have a width equal to the separation distance between the boards (7) and/or the groups of boards (5) of the first structural element (1); the width of the third slots (31) is equal to the thickness of the boards (7) and/or groups of boards (5) of the first or second structural element (1 or 2); the third coupling configuration (30) has a number of third slots (31) equal to the number of boards (7) and/or groups of boards (5) of the first or second structural element (1 or 2); the third projections (32) have a width equal to the separation distance between the boards (7) and/or the groups of boards (5) of the first or second structural element (1 or 2).

3. (canceled)

4. (canceled)

5. The construction system according to claim 1 wherein the number of boards (7) and/or groups of boards (5) forming the third structural element (3) is equal to the number of boards (7) and/or groups of boards (5) forming the first or second structural element (1 or 2) plus one or minus one.

6. The construction system according to claim 1 including: a fourth structural element (4) arranged in the mounting position with the longer edges thereof being vertical, said fourth structural element (4) being formed by at least a plurality of parallel boards (7) and/or groups of boards (5) arranged in the assembly position with the front faces (6) thereof in the vertical position arranged parallel to, facing and spaced from one another; and wherein: the fourth structural element (4) is provided with at least a fourth coupling configuration (40), which has a plurality of fourth straight slots (41), defining fourth projections (42), said fourth slots (41) being made from the head of the fourth structural element (4) to a depth of at least a fifth of the width of the front faces (6) of the first structural element (1), said fourth projections (42) in the mounting position being inserted into said interstitial openings (50) of the structural node, formed by the coupling of the first and second structural elements (1 and 2), from a face opposite the face of insertion of the third projections (32) of the third structural element (3), being the third and the fourth structural elements (3 and 4) aligned.

7. The construction system according to claim 6, wherein the system includes at least one of the following features: the width of the fourth slots (41) is equal to the thickness of the boards (7) and/or groups of boards (5) of the first or second structural element (1 or 2); the fourth coupling configuration (40) has a number of fourth slots (41) equal to the number of boards (7) and/or groups of boards (5) of the first or second structural element (1 or 2); the fourth projections (42) have a width equal to the separation distance between the boards (7) and/or the groups of boards (5) of the first or second structural element (1 or 2).

8. The construction system according to claim 1 wherein the first or second structural elements (1 or 2), the boards (7) of which are not parallel to the boards (7) of the third structural element (3), have a plurality of straight notches (60) arranged in a side face (8) of the boards (7), said notches (60) being made in a side face (8) opposite the side face (8) containing the mentioned first or second projections (12 or 22) and vertically aligned with said first and second projections (12 or 22), or made at the ends of the first or second projections (12 or 22) of the first or second structural element (1 or 2), said notches (60) being complementary to the third slots (31) or fourth slots (41).

9. The construction system according to claim 8, wherein the system includes at least one of the following features: the number of notches (60) is equal to the number of boards (7) and/or groups of boards (5) of the third structural element (3) or of the fourth structural element (4); the thickness of the notches (60) is equal to the thickness of the boards (7) and/or groups of boards (5) of the third structural element (3) or of the fourth structural element (4); the separation distance between the notches (60) is equal to the separation distance between the boards (7) and/or groups of boards (5) of the third structural element (3) or of the fourth structural element (4).

10. The construction system according to claim 1 wherein each structural element has at least two coupling configurations arranged at the ends thereof.

11. The construction system according to claim 1 wherein the first structural element (1) and the second structural element (2) in the mounting position are flush along the upper face thereof.

12. The construction system according to claim 1 wherein each board (7) has been cut by means of a cutting system with numerical control.

13. The construction system according to claim 12, wherein each board (7) includes information that is engraved, cut or printed on the surface thereof during cutting tasks, in reference to the position or placement thereof, or in reference to the position or placement of other construction elements with respect to said board (7).

14. The construction system according to claim 1 wherein the material used in the boards (7) is one of the following: wood, plywood, agglomerated wood, resins, resins and paper.

15. A construction method with three-dimensional structural nodes which includes: generating a computer model of all the boards (7) required, forming the construction system; cutting said boards (7) from flat planks by means of an automated cutting system controlled by numerical control; transporting said already cut boards (7) to the construction site; assembling the boards (7); and wherein the computer model includes at least first and second coupling configurations (10, 20) complementary to one another, each provided with a plurality of first and second slots (11, 21) made in the boards (7); and the automated cutting system making slots (11, 21) in the boards (7) it cuts.

16. The construction method according to claim 15, wherein the automated cutting system includes in each board (7) information in reference to the position and/or placement thereof, and/or information in reference to the position and/or placement of other construction elements with respect to said board (7).

17. The construction method according to claim 15 wherein the computer model decides on the order of cutting the boards (7) depending on at least one of the following variables: the thickness of the board (7) to be cut; the position of the board (7) in the final construction; the order in which each board (7) must be coupled to the rest; the order in which each board (7) must be transported to the construction site; the size of the board (7).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0086] The foregoing and other advantages and features will be better understood from the following detailed description of an embodiment in reference to the attached drawings which must be interpreted in an illustrative and non-limiting manner, in which:

[0087] FIG. 1 shows a perspective view of a first structural element, a second structural element, and a third structural element uncoupled from one another, the first structural element being formed by three boards spaced from one another, the second structural element being formed by three boards spaced from one another, and the third structural element being formed by two groups of boards spaced from one another, each group of boards being formed by two boards;

[0088] FIG. 2 shows a perspective view of the same structural elements shown in FIG. 1, the first and second structural elements being coupled by means of their corresponding coupling configurations, the intersection of the separations between the boards of the first and second structural elements forming interstitial openings having a size and shape complementary to the third projections integrated in the coupling configuration of the third structural element;

[0089] FIG. 3 shows a perspective view of the same structural elements shown in FIG. 2, the third structural element being coupled to the first and second structural elements by means of the insertion of said third projections in said interstitial openings, and also showing a fourth structural element uncoupled from the structural node and located thereabove;

[0090] FIG. 4 shows a perspective view of the same structural elements shown in FIG. 3, the fourth structural element being coupled to the first, second and third structural elements by means of the insertion of said fourth projections in said interstitial openings.

DETAILED DESCRIPTION OF AN EMBODIMENT

[0091] According to the non-limiting embodiment shown in attached FIGS. 1 to 4, a structural node is formed by the mutual coupling of a first structural element 1, a second structural element 2, a third structural element 3 and a fourth structural element 4.

[0092] According to this embodiment, the first structural element 1 and the second structural element 2 are each made up of three boards 7 parallel to and spaced from one another, all of them arranged with their main faces 6 in the vertical direction. The third structural element 3 and the fourth structural element 4 (shown in FIGS. 3 and 4) are each made up of two groups of boards 5 parallel to and spaced from one another, each group of boards 5 in turn being formed by two boards 7 arranged with their main faces 6 in contact with one another. The groups of boards are likewise arranged with their main faces 6 in the vertical direction.

[0093] The first structural element 1 has a first coupling configuration 10 formed by three first straight slots 11 made in each of the boards 7 forming said first structural element 1 from the their upper side faces 8 to half the width of their main faces 6, the first slots 11 of each board 7 facing and being aligned with the first slots 11 of the other boards 7 forming said first structural element 1. A first projection 12 is defined between each of said first slots 11, the three first slots 11 defining two first projections 12.

[0094] In an equivalent manner, the second structural element 2 has a second coupling configuration 20 formed by three second straight slots 21 made in each of the boards 7 forming said second structural element 2, from the lower side faces 8 thereof to half the width of the main faces 6 thereof, the second slots 21 of each board 7 facing and being aligned with the second slots 21 of the other boards 7 forming said second structural element 2. A second projection 22 is defined between each of said second slots 21, the three second slots 21 defining two second projections 22.

[0095] The first coupling configuration 10 is complementary to the second coupling configuration 20, the width of the first slots 11 being equal to the width of the boards 7 forming the second structural element 2, and the width of the second slots 21 being equal to the width of the boards 7 forming the first structural element 1. The width of the first projections 12 define the separation distance between the boards 7 of the second structural element 2, and the width of the second projections 22 define the separation between the boards 7 of the first structural element 1.

[0096] When the first and second structural elements are coupled as shown in FIG. 2 by means of the mutual insertion of the first and second slots 11 and 21, an array defining interstitial openings 50 is obtained.

[0097] In the present embodiment, said interstitial openings 50 are square since the first and second structural elements 1 and 2 are perpendicular, but in another embodiment it is acceptable that both structural elements form with one another an angle other than 90°, creating rhombus-shaped interstitial openings 50 by means of the mutual coupling of first and second slots 11 and 21 going through the thickness of the boards 7 of the first and second structural elements 1 and 2 at said angle other than 90°, said slots therefore not being perpendicular to the main faces 6 of said boards 7.

[0098] Likewise, in the present embodiment shown in the attached drawings, both the first and second structural elements 1 and 2 are horizontal, but in alternative embodiments it is contemplated that the first and/or the second structural element 1 and/or 2 form an angle with respect to the horizontal. In such case, the first or second slots 11 or 21 of the first or second structural elements 1 or 2 which are inclined will not be perpendicular to the side faces 8 of the boards 7 of the corresponding structural element.

[0099] The third structural element 3 shown in FIGS. 1 and 2 has a third coupling configuration 30 formed by three third straight slots 31 made in each of the boards 7 of the groups of boards 5 forming said third structural element 3 from the upper head faces to a depth of half the width of the main face 6 of the first structural element 1, the third slots 31 of each board 7 facing and being aligned with the third slots 31 of the other boards 7 forming said third structural element 3. A third projection 32 is defined between each of said third slots 31, the three third slots 31 defining two third projections 32, and said third projections 32 having a size and shape complementary to those of the interstitial openings 50 to allow a tight fitting.

[0100] Likewise, the fourth structural element 4 has a fourth coupling configuration 40 formed by three fourth straight slots 41 made in each of the boards 7 of the groups of boards 5 forming said fourth structural element 4 from the lower head faces thereof to a depth of half the width of the main face 6 of the first structural element 1, the fourth slots 41 of each board 7 facing and being aligned with the fourth slots 41 of the other boards 7 forming said fourth structural element 4. A fourth projection 42 is defined between each of said fourth slots 41, the three fourth slots 41 defining two fourth projections 42, and said fourth projections 42 having a size and shape complementary to those of the interstitial openings 50 to allow a tight fitting.

[0101] Therefore, the third and fourth coupling configurations 30 and 40 are complementary to the array formed by the coupling of the first and second coupling configurations 10 and 20.

[0102] In the illustrated embodiment, the third projections 32 are inserted into the interstitial openings 50 from the lower face thereof and to a depth equal to half the width of the main faces 6 of the first structural element 1, an upper half of said interstitial openings 50 being empty to receive the fourth projections 42 of the fourth structural element 4.

[0103] In alternative embodiments, the fourth structural element 4 does not exist, the third projections 32 being longer, and the third structural element 3 being able to be inserted from both above and from below the interstitial openings 50.

[0104] The proposed three-dimensional structural nodes allow obtaining a rigid attachment of up to four structural elements, the first and second structural elements 1 and 2 being able to be elements passing through said structural node, such that it allows receiving elements from six different sides, like in the example shown in FIG. 4.

[0105] FIG. 1 attached hereto shows notches 60 made in the boards 7 of the first structural element 1, said notches 60 being made on the lower side face 8, opposite the upper side face 8 in which the first slots 31 have been made, and said slots 60 being aligned and facing the first projections 12. Said notches 60 allow partial insertion of the third structural element 3, which assures a more resistant structural attachment.

[0106] In an alternative embodiment, the distal ends of the first projections 12 can be cut out, being removed with respect to the side face 8, which also works as a notch 60, allowing partial insertion of the fourth structural element 4.

[0107] As will be obvious for a skilled person, said notches could be made in the second structural element 2 in an equivalent manner.