Modular Building Unit, System and Method

Abstract

The invention is for a modular building unit (10, 200, 210) for use in constructing a building. The building unit (10, 200, 210) has a planar body (12) having two major side faces (12.1) and two ends (12.2) between each side face (12.1), and a connection interface (28, 30) provided at each of the ends, for connecting similar building units (10, 200, 210) with complemental connection interfaces. The body (12) comprises three walls (14, 16, 18) arranged side-to-side and transversely spaced from each other, the three walls (14, 16, 18) thus defining two planar spaces (20, 22) therebetween, and a plurality of reinforcing webs (24) in the first space, for providing structural support to the building unit (10, 200, 210). The second space (22) defines at least one hollow cavity for receiving a matched insulation insert (25) thereby to impart insulating properties to the building unit (10, 200, 210).

Claims

1.-18. (canceled)

19. A modular building unit made of a polymeric material for use in constructing a building, the building unit comprising: a planar body having two major side faces and two ends between each side face; and a connection interface provided at each of the ends, thereby to connect building units with complemental connection interfaces, wherein the body further comprises: three walls comprising a first side wall, a middle wall, and a second side wall arranged side-by-side and transversely spaced from each other, the three walls thus defining two planar spaces therebetween, with a first space defined between the first side wall and the middle wall and a second space defined between the middle wall and the second side wall; and a plurality of reinforcing webs extending between the first side wall and the middle wall in the first space, thereby to provide structural support to the building unit, wherein the second space defines at least one hollow cavity extending across at least some of the building unit and operable to receive a matched insulation insert thereby to impart insulating properties to the building unit greater than those of the polymeric material alone, wherein the second space includes locating ridges to locate the insulation insert therein, wherein the second space includes at least one support web extending between the second side wall and the middle wall, the second space thus being divided into a plurality of laterally spaced apart sub-cavities, and wherein the support web or at least one of the support webs is inclined about an upright axis, thereby to increase overlap of ends of adjacent sub-cavities and any insulating inserts therein.

20. The modular building unit as claimed in claim 19, wherein the first side wall and middle wall are spaced further apart than the middle wall and the second side wall, the second space thus being narrower than the first space.

21. The modular building unit as claimed in claim 19, wherein the insulation insert is receivable in each one of the sub-cavities.

22. The modular building unit as claimed in claim 19, wherein the locating ridges are upright and are configured to space the insulation insert from the second wall and the middle wall.

23. The modular building unit as claimed in claim 19, wherein the connection interfaces are complemental but opposite, and wherein one end of the unit includes a male connection interface and the other end includes a female connection interface.

24. The modular building unit as claimed in claim 19, wherein the male and female connection interfaces are resilient and provide a snap-fit connection.

25. An assembled building unit comprising the modular building unit as claimed in claim 19, which includes at least one insulating insert within the second space.

26. The assembled building unit as claimed in claim 25, in which the insulating insert is fire resistant.

27. A building system which includes a plurality of modular building units according to claim 19.

28. The building system as claimed in claim 27, which includes an adaptor unit comprising a body having either a male or female connection interface on each one of opposite sides for use as an intermediary to connect male-male or female-female connection interfaces of two modular building units together.

29. The building system as claimed in claim 27, which includes a pillar unit which is square in cross-sectional profile and which provides four connection interfaces, one on each side, for complementary connection to a modular building unit or any other unit in the system.

30. The building system as claimed in claim 27, which includes a roof support unit with an inclined top surface for locating and supporting roof panels.

31. The building system as claimed in claim 27, which includes a centre beam comprising: a base; an elongate beam member projecting upwardly from the base; and a pair of declined wing members projecting outwardly and downward from the beam member, for use at an apex of a roof.

32. The building system as claimed in claim 27, which includes one or more of the following structural units: a floor beam unit; a T combiner unit; a cover strip for connection to an unused pillar connection interface; a door adaptor unit; and a window adaptor unit.

33. A method of constructing a building from modular building units, the method including: connecting together a plurality of building units as claimed in claim 19; and inserting an insulation insert into the second space of at least one of the building units, thereby to insulate the building unit.

34. A building or structure comprising a plurality of the modular building units as claimed in claim 19.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0060] The invention will now be described, by way of example, with reference to the accompanying diagrammatic drawings.

[0061] In the drawings:

[0062] FIG. 1 shows a top plan view of a panel unit in accordance with the invention which forms part of a building system in accordance with the invention;

[0063] FIG. 2 shows a top plan view of the panel unit of FIG. 1 including an insulation insert;

[0064] FIG. 3 shows ends of two adjacent panel units of FIG. 1 not yet connected;

[0065] FIG. 4 shows the ends of the two adjacent panel units of FIG. 3 connected;

[0066] FIG. 5 shows a top plan view of an adaptor unit forming part of the building system;

[0067] FIG. 6 shows a top plan view of a pillar unit forming part of the building system;

[0068] FIG. 7 shows an exploded view of a T-junction forming part of the building system;

[0069] FIG. 8 shows an assembled view of the T-junction of FIG. 7 with insulation inserts;

[0070] FIGS. 9-14 show plan or elevation views of a selection of additional constructional units which may be used in the building system;

[0071] FIG. 15 shows a top plan view of an alternative panel unit in accordance with the invention;

[0072] FIG. 16 shows a top plan view of the panel unit of FIG. 15 including plural insulation inserts;

[0073] FIG. 17 shows a top plan view of another embodiment of a pillar unit forming part of the building system;

[0074] FIG. 18 shows an elevation view of a window adaptor unit forming part of the building system; and

[0075] FIG. 19 shows a top plan view of a third embodiment of a panel unit in accordance with the invention.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENT

[0076] The following description of the invention is provided as an enabling teaching of the invention. Those skilled in the relevant art will recognise that many changes can be made to the embodiment described, while still attaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be attained by selecting some of the features of the present invention without utilising other features. Accordingly, those skilled in the art will recognise that modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances, and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not a limitation thereof.

[0077] FIG. 1 shows a building unit, and specifically a panel unit 10, in accordance with the invention. The panel unit 10 has a body 12 made of thermoplastic. The panel unit 10 is about 472 mm wide×indefinite length×70 mm thick. The body 12 has two major side faces 12.1 and two minor end faces 12.2 at the ends of, and between, each side face 12.1.

[0078] The panel unit 10 comprises three walls 14-18, namely, a first side wall 14, a middle wall 16, and a second side wall 18. The walls 14-18 are thin and planar. The walls 14-18 are transversely spaced a short distance apart thereby to define two spaces 20-22, namely a first space 20 defined between the first side wall 14 and the middle wall 16, and a second space 22 defined between the middle wall 16 and the second side wall 18.

[0079] A plurality of transversely extending reinforcing webs 24 extend between the first side wall 14 and the middle wall 16 in the first space 20. The webs 24 impart stiffness and structural rigidity to the panel unit 10. In contrast, the second space 22 does not include webs, or includes fewer webs. Accordingly, the second space 22 thus defines a hollow cavity (or a series of hollow cavities) extending across a majority of the panel unit 10. The hollow cavity 22 is configured to receive a matched planar insulation insert 25 thereby to impart insulating, in particular, fire resistance properties to the panel unit 10 greater than those of the thermoplastic material alone.

[0080] FIG. 2 shows the insulation insert 25 located in the hollow cavity 22. The insulation insert 25 need not always be provided in the hollow cavity 22—it may depend on the position of the panel unit 10 with a building whether or not insulation is required. The insulation insert 25 is simply slid into the cavity 22 by hand and retained in place by a series of locating ridges 26 within the cavity 22.

[0081] A connection interface 28-30 is provided at each end 12.2 of the panel unit 10. The connection interfaces 28-30 are complemental but opposite. The connection interface 28 on one end face 12.2 is a female interface and has a pair of opposed resiliently deformable hook members 32. The other connection interface 30 on the other end face 12.2 is a male connection interface and has a pair of opposite catch members 34 operable to receive the hook formations 32 and prevent transverse withdrawal thereof.

[0082] FIGS. 3-4 show the interconnection of the two connection interfaces 28-30 from two separate adjacent panel units 10 in more detail. The two connection interfaces 28-30 can engage and latch by transversal insertion of one into the other. An inclined surface 36 on the male connection formation 30 deforms the hook member 32 gently outwardly until it snaps into place in the catch member 34 where it cannot be withdrawn in the opposite direction. (The two panel units 10 can be separated by sliding them apart in a direction parallel to the ends 12.2, but not transversely away from the ends 12.2.) In this fashion, an indefinite number of panel units 10 can be connected end-to-end in a line to form a wall or other linear building structure.

[0083] FIG. 5 shows an adaptor unit 50 which has a body 52 made of thermoplastic material (like that of the panel unit 10). The body 52 defines opposite connection interfaces 54-56 which, in this example, are both male connection interfaces and are similar or identical to the male connection interface 30 of the panel unit 10. Each connection interface 54-56 has an oblique face 36 and a catch member 34 arranged rearwardly therefrom.

[0084] The adaptor 50 may be used as part of a building system, in accordance with the invention, including a plurality of the panel units 10.

[0085] FIG. 6 shows a top plan view of a pillar member 60 used in the building system. The pillar member 60 has a generally square body 62 with a connection interface 64 at each of the four sides. Each connection interface 64 is similar to the female connection interface 28 of the panel unit 10, except that hook members 66 are configured slightly differently and that a ridge 68 is provided in the middle of the connection interface 64.

[0086] Each connection interface 64 can therefore receive either the male connection interface 30 of the panel unit 10 or the male connection interface 56 of the adaptor unit 50. (The connection interface 64 cannot receive the other male connection interface 54 of the adaptor unit 50 because the ridge 68 cannot be accommodated.)

[0087] The body 62 defines a cruciform hollow interior 70 which can accommodate an insulating strip orientated in one of two directions (see further below) or an x-shaped insulation insert.

[0088] FIGS. 7-8 show part of an example system 100 of three panel units 10, an adaptor unit 50 and a pillar unit 60 arranged to form a T-junction with partial insulation. In this T-junction, only three connection interfaces 64 of the pillar unit 60 have been used. Because the pillar unit 60 has only four female connection interfaces 64, it can only accept complemental male connection interfaces from the units 10, 50 which are connected to it.

[0089] Two panel units 10 (on the right and the bottom of the pillar unit 60 in the figure) are connected directly to the pillar unit 60 using their complemental male connection interfaces 30. The ridges 68 of the pillar unit 60 are accommodated neatly within the corresponding grooves of the panel units 10.

[0090] The orientation of the panel unit 10 on the left might not have permitted its male connection interface 30 to be adjacent the pillar unit 60. Accordingly, the adaptor unit 50 is used to allow the female connection interface 28 of the panel member 10 to connect indirectly with the pillar member 60. The adaptor unit 50 must be orientated such that its groove 59 accommodates the ridge 68 of the pillar unit 60.

[0091] FIG. 8 shows the system 100 assembled. The respective units 10, 50, 60 are moved transversely (relative to the height axis or their upright ends 12.2) to snap together by engagement of the hook members 32 with the catch members 34. (Instead, if desired, the units 10, 50, 60 could be slid longitudinally (relative to the edges 12.2) together but it will usually be more practical to snap them together.)

[0092] FIG. 8 also illustrates the arrangement of insulation inserts 25, 81. The panel insulation inserts 25 have been placed in the hollow cavity 22 of each of the left and right panel units 10. A pillar insulation insert 81, in the form of an elongate strip, has been placed in the cruciform hollow interior 70 to be parallel with the other insulation inserts 25. Thus, a continuous fire resistant barrier 25, 81 has been created along a wall (formed by the left and right panel units 10) which may be deemed to require non-inflammable or other insulating properties. If desired, any uninsulated units (e.g., the adaptor unit 50) could include cladding in the form of a metal strip or the like.

[0093] By varying the arrangement of units 10, 50, 60, other configurations can be achieved, including a four way junction (with a panel unit 10 connected directly or indirectly via an adaptor unit 50 to each side of the pillar unit 60), two way junction, whether L-shaped or straight. However, use of an adaptor 50 only may be a more efficient way to achieve a straight junction.

[0094] FIGS. 9-14 show various additional constructional units 110-160.

[0095] FIG. 9 shows a pillar blank cover unit 110 which can be used to cover unused connection interfaces of the pillar unit 60. For example, in FIGS. 7-8, the pillar blank cover unit 110 may be applied to the connection interface 64 at the top where no panel unit 10 or adaptor unit 50 is connected. This closes off any unused connection interfaces 64, creating a neater finish.

[0096] FIG. 10 shows a door adaptor unit 120 which can be to create part of a door frame.

[0097] FIGS. 11-12 show respectively a floor beam unit 130 and a T combiner unit 140 which can be used to impart desired finishes to the system 100.

[0098] FIG. 13 shows a centre beam unit 150 which comprises a base 152, an elongate beam member 154 projecting upwardly from the base 152 and a pair of declined wing members 156 projecting outwardly and downwardly from the beam member 154. The centre beam unit 150 is used to create an apex of a roof.

[0099] FIG. 14 shows a roof wall beam unit 160 which has an inclined top surface 162. The roof wall beam unit 160 and the centre beam unit 150 together serve to locate and support roof panels (not illustrated).

[0100] FIG. 15 shows an alternative embodiment of a panel unit 200, in accordance with the invention. The panel unit 200 is similar to that of FIG. 1, but in this embodiment, a second space 204 has obliquely extending webs 202 thus defining a plurality of smaller hollow cavities 204.1-204.3 (collectively forming the second space 204). This panel unit 200 may be desirable from a structural perspective or may be necessitated by limitations in extrusion or other manufacturing techniques.

[0101] FIG. 16 shows the panel unit 200 including a plurality of insulation inserts 206.1-206.3 respectively placed in the hollow cavities 204.1-204.3. The outer insulation inserts 206.1, 206.3 are the same shape (with one being upside down relative to the other) and the middle insulation insert 206.2 is a different shape. The webs 202 are oblique or inclined to assist in the maintenance of a continuous fireproof barrier.

[0102] FIG. 17 shows a top plan view of a second embodiment of a pillar member 170, similar to the pillar member 60 as shown in FIG. 6. The pillar member 170 excludes the cruciform hollow interior 70 as shown in FIG. 6 but still includes the ridges 68. The pillar insulation insert 81 can be accommodated by the ridges 68 alone.

[0103] FIG. 18 shows a window adaptor unit 180, which has a grooved frame 182 which serves to locate and support windows (not illustrated).

[0104] FIG. 19 shows a third embodiment of a panel unit 210, in accordance with the invention. The panel unit 210 is similar to those of FIGS. 1 and 15, but in this embodiment, a differing configuration of reinforcing webs 214 is provided in a first space 220. Also, the configurations of locating ridges 216 differ slightly. This panel unit 210 may be desirable from a structural perspective or may be desired for ease of extrusion/moulding or other manufacturing technique.

[0105] The Applicant believes that the invention as exemplified provides several advantages. The provision of hollow cavities 22, 70 to accommodate an insulation insert 25, 81 (or any other kind of insulating material, e.g., stuffing). This allows use of relatively cheap and easy to manufacture units (e.g., the panel unit 10) to be used without the need for additional cladding. Where insulation is not required, it need not be used. Where insulation is required, it can simply be inserted or otherwise provided in the cavities 22, 70. This procedure is quick and may be done without special tools or skills. It does not add significantly to construction time.