Modular building unit, system and method

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).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is the United States national phase of International Application No. PCT/ZA2015/050014 filed Oct. 21, 2015, and claims priority to South African Patent Application No. 2014/07650 filed Oct. 21, 2014, the disclosures of which are hereby incorporated in their entirety by reference.

BACKGROUND OF THE INVENTION

Field of Invention

The present application relates to modular or prefabricated buildings. More particularly, it relates to a modular building unit, system and method, for example for modular prefabricated construction of houses, buildings, or like structures.

Description of Related Art

Plastic modules which fit together to form a building, like a house, are used in various industries. Use of plastic, specifically thermoplastic, is convenient because it is cheap to manufacture and handle. It can be designed to any shape which can practicably be moulded (e.g., using plastic extrusion and vacu-forming processes).

U.S. Pat. No. 7,797,897 discloses a system which includes a plurality of modular wall units which are interconnectable by means of joiner units. The wall units are planar and have a connection interface at each end. The connection interfaces are the same (e.g., female) and therefore cannot be directly connected to each other; they must be interconnected by means of the complemental joiner unit which has a pair of complemental connection interfaces (e.g., male).

U.S. Pat. No. 8,640,410 also discloses a similar modular wall unit. The wall unit of U.S. Pat. No. 8,640,410 is also planar, made of a plastic, and includes a connection interface at each end. However, the connection interfaces are not the same—they are complemental, e.g., one end has a female interface and the other end has a male interface. This permits the wall units to be connected directly to each other without the need for joiner units.

A potential drawback of these modular systems, and indeed all systems made of plastic, is that they lack certain characteristics required for building structures, e.g., insulation, and more specifically fire resistance. Building codes in many jurisdictions require that some walls, e.g., exterior walls, of buildings have a minimum amount of fire resistance. This necessitates cladding of the wall units, which adds to the cost of the building, adds to construction time, and increases the level of complexity of the assembly. The cladding may also impart other useful qualities, e.g., heat insulation, sound insulation, etc., depending on the cladding material used.

Metal building units, e.g., as disclosed in U.S. Pat. No. 3,001,613, may have some degree of inherent fire resistance but add other complexities, e.g., cost and manufacturing difficulties. The Applicant thus does not consider any metal modular building units to be of relevance to the present invention. Thus a modular building unit (and system formed therewith) is desired which has the advantages of plastic or polymer-based building units, but which has better insulating characteristics than other systems.

The Applicant thus desires a modular building unit (and system formed therewith) which has the advantages of plastic or polymer-based building units, but which has better insulating characteristics than other systems of which the Applicant is aware.

SUMMARY OF INVENTION

According to one aspect of the invention, there is provided a modular building unit made of a polymeric material and for use in constructing a building, the building unit including:a planar body having two major side faces and two ends between each side face; anda connection interface provided at each of the ends, thereby to connect similar building units with complemental connection interfaces, wherein the body further comprises:three walls (respectively a first side wall, a middle wall, and a second side wall) arranged side-to-side and transversely spaced a short distance from each other, the three walls thus defining two planar spaces therebetween, that is, 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; anda 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.

In the context of this specification, the term “insulating” may refer generally to fire resistance. It may also refer to other characteristics, such as noise insulation. In the context of the three walls, the distance they are spaced apart is “short” relative to the height or length of the modular building unit.

All of the prior art building units (e.g., those of U.S. Pat. No. 7,797,897 and U.S. Pat. No. 8,640,410) of which the Applicant is aware comprise only two walls (and not three) with reinforcing webs extending between the two walls. The prior art building units therefore lack the second space.

The building unit (in accordance with the present invention) may be of PVC or of thermoplastic. The building unit may be manufactured by a plastic extrusion process or a moulding process. The invention thus extends to an extrusion and injection mould operable to extrude or mould the building unit in accordance with the present invention.

The building unit may be used for providing panels or walls and is further referred to as a panel unit for ease of explanation.

The walls may be unequally spaced apart. For instance, the first side wall and the middle wall may be spaced further apart than the middle wall and the second side wall. Consequently, the first and second spaces may be different thicknesses. For example, the first space (with the reinforcing webs) may be thicker than the second space. The first side wall and the middle wall may be spaced 2-10 cm apart, e.g., 4 cm apart. The middle wall and the second side wall may be 1-5 cm apart, e.g., 2 cm apart.

The panel unit may be sized according to an intended size or configuration of the building which the panel unit will be used to construct. A standard panel unit may be 472 mm wide and may be any practicable length.

The reinforcing webs in the first space may be spaced equal distances apart. The reinforcing webs may be spaced 5 cm to 0.2 m apart, e.g., 75 cm apart.

The second space may also include some support webs extending between the middle wall and the second side wall, but not as many reinforcing webs as there are in the first space. The support webs (if present) in the second space may be oblique or inclined relative to an upright axis. The second space may thus define a plurality of hollow cavities or sub-cavities between the support webs, the hollow cavities each operable to receive an insulation insert. The second space may include locating ridges to locate an insulation insert therein.

The insulation insert (referred to as the wall insulation insert) may be thin. The wall insulation insert may be planar, and panel-like or strip-like, depending on the size and shape cavity. The wall insulation insert may be made of fire resistance plaster board or other fire resistance material.

The wall insulation insert may have one or more of the following insulation properties:fire resistance sufficient to meet building codes/regulations in the jurisdiction in which it is being used;thermal insulation; and/orsound insulation.

(It should be noted that it may not necessarily be required to locate a building insert in each hollow cavity. For example, a building may have both exterior walls and interior walls. It may be a building regulation or code in a particular jurisdiction that outer walls must have certain characteristics, e.g., a minimum degree of fire resistance. Thus, it may be appropriate to place insulation inserts in the hollow cavities of the panel units forming the exterior walls, but not in the hollow cavities of the panel units forming the interior walls. In this fashion, costs and complexity can be reduced by only applying the insulation inserts to walls where they are required.)

The connection interfaces may be complemental but opposite. One end of the panel unit may have a male connection interface while the other end may have a female connection interface. Thus, a particular connection interface (e.g., a female connection interface) of one panel unit may be operable to interface with, and connect directly to, an opposite connection interface (e.g., a male connection interface) of a similar or identical adjacent panel unit. Conversely, the same connection interfaces of panel units may not be capable of direct connection to each other; however, an adaptor unit may be provided (see further below).

The connection interfaces may provide a snap-fit. Thus, one connection interface may include a hook or latch member while the other may include a catch or detent member. At least one of the members may be resiliently deformable. The hook member may be resiliently deformable.

The connection interfaces may permit two adjacent panel units to be snapped together by sliding them together in a direction transverse to the edges. Usually, when the panel units are in an operatively upright position, this may entail sliding the panel units horizontally together and causing the respective connection interfaces to snap together. The connection interfaces may prevent or at least inhibit disconnection in the same transverse direction. If desired, the connection interfaces may be reinforced, e.g., by application of an adhesive or a cement.

The connection interfaces may be disconnectable (and connectable) by sliding the panel units in a direction parallel to the edges. Usually, when the panel units are in an operatively upright position, this may entail sliding the panel units vertically to lift one clear of the other.

The invention extends to a building system which includes a plurality of panel units as defined above.

The system may include an adaptor unit. The adaptor unit may be about the same thickness as the panel units but much narrower. The adaptor unit may comprise a body having a connection interface on each side. The connection interfaces may be matched, that is, both of the same type (e.g., both male connection interfaces).

Where the panel unit has complemental but opposite connection interfaces (e.g., male-female), it will not be possible to connect the same connection interfaces (e.g., female-female) directly to each other. Accordingly, two panel units may be connected to each other indirectly with the same (not opposite or complemental) connection interfaces by using the adapter unit as an intermediary. For example, two female connection interfaces provided on adjacent panel units may be interconnected by using opposite and complemental male connection interfaces provided on the adaptor unit.

The building system may include a pillar unit. The pillar unit may be square in cross-sectional profile and may provide four connection interfaces, one on each side. The connection interfaces on the pillar unit may all be the same, e.g., female. A panel unit may be connectable directly to the pillar unit using a complemental connection interface, e.g., male on the panel unit to female on the pillar unit. Instead, the panel unit may be connected indirectly to the pillar unit using the same (not complemental) connection interface via the adaptor unit.

The pillar unit may be operable to create;a four-way junction, when four panel units are connected directly or indirectly to all four connection interfaces;a three-way or T-junction, when three panel units are connected directly or indirectly to three of the connection interfaces; anda two-way or L-shaped junction, when two panel units are connected directly or indirectly to two adjacent connection interfaces.

The pillar unit and/or the adaptor unit may be of the same material as the panel unit, e.g., moulded thermoplastics.

The pillar unit may define a hollow interior to receive an insulation insert. The pillar insulation insert may be shaped or sized differently from the building insulation insert. The hollow interior may be cruciform or X-shaped. Accordingly, the hollow interior may receive differently shaped pillar insulation inserts. In one example, the hollow insulation insert may be a flat strip, thus being able to be orientated in the X-shaped hollow in one of two orientations. The strip may be orientated co-planar with an adjacent panel unit, thus being parallel with the hollow cavity of that panel unit, thereby to provide continuous or near-continuous insulation.

The building system may include a roof support unit. The roof support unit may have an inclined top surface.

The system may include a centre beam unit, for use at an apex of a roof. The centre beam unit may comprise:a base;an elongate beam member projecting upwardly from the base; anda pair of declined wing members projecting outwardly and downwardly from the beam member.

The system may include other structural units. The system may include one or more of:a floor beam unit;a T combiner unit;a cover strip for connection to an unused pillar connection interface;a door adaptor unit; and/ora window adaptor unit.

Some or all of the units may include mechanical connection formations, such as tongue and groove, hook and catch, frictional interference fits, etc.

Some or all units may still include cladding, if desired.

The invention extends to a method of building, the method including:connecting together a plurality of panel units, as defined above; andinserting an insulation insert into the hollow cavity of at least one of the panel units, thereby to insulate the panel unit.

The step of inserting may be done prior to connection of the panel units, during connection, or after connection.

The invention extends to a building or structure comprising the panel units as defined above.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

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.

FIG. 1shows a building unit, and specifically a panel unit10, in accordance with the invention. The panel unit10has a body12made of thermoplastic. The panel unit10is about 472 mm wide×indefinite length×70 mm thick. The body12has two major side faces12.1and two minor end faces12.2at the ends of, and between, each side face12.1.

The panel unit10comprises three walls14-18, namely, a first side wall14, a middle wall16, and a second side wall18. The walls14-18are thin and planar. The walls14-18are transversely spaced a short distance apart thereby to define two spaces20-22, namely a first space20defined between the first side wall14and the middle wall16, and a second space22defined between the middle wall16and the second side wall18.

A plurality of transversely extending reinforcing webs24extend between the first side wall14and the middle wall16in the first space20. The webs24impart stiffness and structural rigidity to the panel unit10. In contrast, the second space22does not include webs, or includes fewer webs. Accordingly, the second space22thus defines a hollow cavity (or a series of hollow cavities) extending across a majority of the panel unit10. The hollow cavity22is configured to receive a matched planar insulation insert25thereby to impart insulating, in particular, fire resistance properties to the panel unit10greater than those of the thermoplastic material alone.

FIG. 2shows the insulation insert25located in the hollow cavity22. The insulation insert25need not always be provided in the hollow cavity22—it may depend on the position of the panel unit10with a building whether or not insulation is required. The insulation insert25is simply slid into the cavity22by hand and retained in place by a series of locating ridges26within the cavity22.

A connection interface28-30is provided at each end12.2of the panel unit10. The connection interfaces28-30are complemental but opposite. The connection interface28on one end face12.2is a female interface and has a pair of opposed resiliently deformable hook members32. The other connection interface30on the other end face12.2is a male connection interface and has a pair of opposite catch members34operable to receive the hook formations32and prevent transverse withdrawal thereof.

FIGS. 3-4show the interconnection of the two connection interfaces28-30from two separate adjacent panel units10in more detail. The two connection interfaces28-30can engage and latch by transversal insertion of one into the other. An inclined surface36on the male connection formation30deforms the hook member32gently outwardly until it snaps into place in the catch member34where it cannot be withdrawn in the opposite direction. (The two panel units10can be separated by sliding them apart in a direction parallel to the ends12.2, but not transversely away from the ends12.2.) In this fashion, an indefinite number of panel units10can be connected end-to-end in a line to form a wall or other linear building structure.

FIG. 5shows an adaptor unit50which has a body52made of thermoplastic material (like that of the panel unit10). The body52defines opposite connection interfaces54-56which, in this example, are both male connection interfaces and are similar or identical to the male connection interface30of the panel unit10. Each connection interface54-56has an oblique face36and a catch member34arranged rearwardly therefrom.

The adaptor50may be used as part of a building system, in accordance with the invention, including a plurality of the panel units10.

FIG. 6shows a top plan view of a pillar member60used in the building system. The pillar member60has a generally square body62with a connection interface64at each of the four sides. Each connection interface64is similar to the female connection interface28of the panel unit10, except that hook members66are configured slightly differently and that a ridge68is provided in the middle of the connection interface64.

Each connection interface64can therefore receive either the male connection interface30of the panel unit10or the male connection interface56of the adaptor unit50. (The connection interface64cannot receive the other male connection interface54of the adaptor unit50because the ridge68cannot be accommodated.)

The body62defines a cruciform hollow interior70which can accommodate an insulating strip orientated in one of two directions (see further below) or an x-shaped insulation insert.

FIGS. 7-8show part of an example system100of three panel units10, an adaptor unit50and a pillar unit60arranged to form a T-junction with partial insulation. In this T-junction, only three connection interfaces64of the pillar unit60have been used. Because the pillar unit60has only four female connection interfaces64, it can only accept complemental male connection interfaces from the units10,50which are connected to it.

Two panel units10(on the right and the bottom of the pillar unit60in the figure) are connected directly to the pillar unit60using their complemental male connection interfaces30. The ridges68of the pillar unit60are accommodated neatly within the corresponding grooves of the panel units10.

The orientation of the panel unit10on the left might not have permitted its male connection interface30to be adjacent the pillar unit60. Accordingly, the adaptor unit50is used to allow the female connection interface28of the panel member10to connect indirectly with the pillar member60. The adaptor unit50must be orientated such that its groove59accommodates the ridge68of the pillar unit60.

FIG. 8shows the system100assembled. The respective units10,50,60are moved transversely (relative to the height axis or their upright ends12.2) to snap together by engagement of the hook members32with the catch members34. (Instead, if desired, the units10,50,60could be slid longitudinally (relative to the edges12.2) together but it will usually be more practical to snap them together.)

FIG. 8also illustrates the arrangement of insulation inserts25,81. The panel insulation inserts25have been placed in the hollow cavity22of each of the left and right panel units10. A pillar insulation insert81, in the form of an elongate strip, has been placed in the cruciform hollow interior70to be parallel with the other insulation inserts25. Thus, a continuous fire resistant barrier25,81has been created along a wall (formed by the left and right panel units10) which may be deemed to require non-inflammable or other insulating properties. If desired, any uninsulated units (e.g., the adaptor unit50) could include cladding in the form of a metal strip or the like.

By varying the arrangement of units10,50,60, other configurations can be achieved, including a four way junction (with a panel unit10connected directly or indirectly via an adaptor unit50to each side of the pillar unit60), two way junction, whether L-shaped or straight. However, use of an adaptor50only may be a more efficient way to achieve a straight junction.

FIG. 9shows a pillar blank cover unit110which can be used to cover unused connection interfaces of the pillar unit60. For example, inFIGS. 7-8, the pillar blank cover unit110may be applied to the connection interface64at the top where no panel unit10or adaptor unit50is connected. This closes off any unused connection interfaces64, creating a neater finish.

FIG. 10shows a door adaptor unit120which can be to create part of a door frame.

FIGS. 11-12show respectively a floor beam unit130and a T combiner unit140which can be used to impart desired finishes to the system100.

FIG. 13shows a centre beam unit150which comprises a base152, an elongate beam member154projecting upwardly from the base152and a pair of declined wing members156projecting outwardly and downwardly from the beam member154. The centre beam unit150is used to create an apex of a roof.

FIG. 14shows a roof wall beam unit160which has an inclined top surface162. The roof wall beam unit160and the centre beam unit150together serve to locate and support roof panels (not illustrated).

FIG. 15shows an alternative embodiment of a panel unit200, in accordance with the invention. The panel unit200is similar to that ofFIG. 1, but in this embodiment, a second space204has obliquely extending webs202thus defining a plurality of smaller hollow cavities204.1-204.3(collectively forming the second space204). This panel unit200may be desirable from a structural perspective or may be necessitated by limitations in extrusion or other manufacturing techniques.

FIG. 16shows the panel unit200including a plurality of insulation inserts206.1-206.3respectively placed in the hollow cavities204.1-204.3. The outer insulation inserts206.1,206.3are the same shape (with one being upside down relative to the other) and the middle insulation insert206.2is a different shape. The webs202are oblique or inclined to assist in the maintenance of a continuous fireproof barrier.

FIG. 17shows a top plan view of a second embodiment of a pillar member170, similar to the pillar member60as shown inFIG. 6. The pillar member170excludes the cruciform hollow interior70as shown inFIG. 6but still includes the ridges68. The pillar insulation insert81can be accommodated by the ridges68alone.

FIG. 18shows a window adaptor unit180, which has a grooved frame182which serves to locate and support windows (not illustrated).

FIG. 19shows a third embodiment of a panel unit210, in accordance with the invention. The panel unit210is similar to those ofFIGS. 1 and 15, but in this embodiment, a differing configuration of reinforcing webs214is provided in a first space220. Also, the configurations of locating ridges216differ slightly. This panel unit210may be desirable from a structural perspective or may be desired for ease of extrusion/moulding or other manufacturing technique.

The invention as exemplified herein provides several advantages. The provision of hollow cavities22,70to accommodate an insulation insert25,81(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 unit10) 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 cavities22,70. This procedure is quick and may be done without special tools or skills. It does not add significantly to construction time.