Abstract:
Embodiments of the present invention provide a modular frame system for building construction using prefabricated frame components that can be assembled at the construction site easily and quickly. A number of connection mechanisms or joints are employed to connect the beams, columns, trusses, bases and the like. More specifically, they include connections for column to base, column to beam, truss/beam to column, truss to column, and truss to beam. In accordance with an aspect of the invention, a modular frame apparatus for building construction comprises a column; a plurality of prefabricated, modular structural components to be connected to the column; and a plurality of connecting mechanisms each configured and prefabricated to connect one or more of the plurality of modular structural components to the column in a modular manner to form a building module for a building.

Description:
FIELD OF THE INVENTION 
       [0001]    The invention relates generally to modular building construction and, more particularly, to a modular frame system using light-gage metal in building construction and connection mechanisms for columns, beams, trusses, and other frame components designed to provide a modular assembly building construction that makes efficient use of materials and labor. 
       BACKGROUND OF THE INVENTION 
       [0002]    Modular building construction can have the advantages of cost-effectiveness and ease of assembly over convention building construction. Fully modular building frame systems, however, are still not commonly seen. As conventional building construction costs continue to escalate, modular building construction that can provide savings in cost of labor and materials presents an attractive alternative. The modular building components can be manufactured on-site or off-site, and then moved into position to form the building frame. There is a need for a more fully modular frame system that is easy and quick to construct and makes efficient use of materials and labor. 
       SUMMARY OF THE INVENTION 
       [0003]    Embodiments of the invention provide a modular frame system for building construction using prefabricated frame components that can be assembled at the construction site easily and quickly. A number of connection mechanisms or joints are employed to connect the beams, columns, trusses, bases and the like. More specifically, they include connections for column to base, column to beam, truss/beam to column, truss to column, and truss to beam. With proper design of these connections, the whole frame system can be modularized into relatively few standard sizes and types. The modular frame system is then used to construct a building with specially designed light gage metal studs, concrete slabs, and other prefabricated components. The frame system can be fully modularized, and the frame construction procedure is analogous to a furniture assembly process. 
         [0004]    In accordance with an aspect of the present invention, a modular frame apparatus for building construction comprises a column; a plurality of prefabricated, modular structural components to be connected to the column; and a plurality of connecting mechanisms each configured and prefabricated to connect one or more of the plurality of modular structural components to the column in a modular manner to form a building module for a building. 
         [0005]    In some embodiments, the modular structural components include a base. The connecting mechanisms include a column sleeve having an outer shape generally matching a shape of a hollow interior of the column and an outer size slightly smaller than a size of the hollow interior of the column to fit inside the column; a footing anchor fastener to fasten the column sleeve to the base; a height adjusting ring having a dimension generally matching the dimension of the hollow column and being disposed between the column and the base and being disposed around the column sleeve, the height adjusting ring having a height selected to adjust the height of the column relative to the base; and a column fastener to fasten the column to the column sleeve. The column sleeve includes an integrally formed nut; and the column fastener comprises a threaded bolt to threadingly engage the integrally formed nut to fasten the column to the column sleeve. 
         [0006]    In specific embodiments, the column includes at least one slot in a column wall between an exterior and a hollow interior of the column. The modular structural components include a beam. The connecting mechanisms include a column connecting member attached to the beam, the column connecting member having a longitudinal body extending across and received into the slot of the column, and a transverse flange connected to the longitudinal body and having a slanted surface facing inwardly toward the beam; and a wedge-shaped choke configured to be disposed between the slanted surface of the transverse flange and the column wall. The wedge-shaped choke includes a slot to receive the longitudinal body of the column connecting member. 
         [0007]    In some embodiments, the column includes a plurality of openings. The modular structural components include a beam. The connecting mechanisms include a pair of L-shaped beam holding bars attached to a hollow interior of the beam, the beam holding bars having threaded holes matching the holes on the column; and a plurality of fasteners configured to fasten the beam holding bars to the column via the holes of the beam holding bars and the holes on the column. The beam holding bars are disposed slightly inward from an end of the beam facing the column. 
         [0008]    In some embodiments, the modular structural components include a beam. The connecting mechanisms include a tongue-in-groove connection The column includes one part of the tongue-in-groove connection and the beam includes another part of the tongue-in-groove connection. 
         [0009]    In some embodiments, the column is a lower column. The modular structural components include an upper column to be disposed above the lower column. The connecting mechanisms include a transitional column sleeve having a shape generally matching shapes of the upper and lower columns and having a size slightly smaller than sizes of the upper and lower columns to fit inside hollow interiors of the upper and lower columns; and fasteners to fasten at least one of the upper and lower columns to the transitional column sleeve. The column transitional sleeve may include integrally formed nuts to be threadingly connected by the fasteners to fasten the column transitional sleeve to at least one of the upper and lower columns. The column transitional sleeve may include at least one slot matching at least one slot of one of the upper and lower columns. The column transitional sleeve may include a plurality of holes matching openings in at least one of the upper and lower columns. 
         [0010]    In specific embodiments, the modular structural components include a truss or a beam. The connecting mechanisms include a holder having a holder base connected to the column and a pair of spaced holder supports extending from the holder base to receive the truss or beam therebetween, the pair of spaced holder supports each including an aperture for a fastener to pass therethrough to fasten the truss or beam to the pair of spaced holder supports. The column includes a column cap having a plurality of holes for connecting the holder base of the holder to the column cap via any one of the holes at selected location and orientation. 
         [0011]    In some embodiments, the column includes at least one slot in a column wall between an exterior and a hollow interior of the column. The modular structural components include a truss. The connecting mechanisms include a column connecting member attached to the truss, the column connecting member having a longitudinal body extending across and received into the slot of the column, and a transverse flange connected to the longitudinal body and having a slanted surface facing inwardly toward the truss; and a wedge-shaped choke configured to be disposed between the slanted surface of the transverse flange and the column wall. 
         [0012]    In specific embodiments, the column includes at least one slot in a column wall between an exterior and a hollow interior of the column. The modular structural components include a truss. The connecting mechanisms include a column connecting member attached to the truss, the column connecting member having a longitudinal body extending across and received into the slot of the column, a distal transverse flange connected to the longitudinal body to be disposed at an outer surface of the column wall, and a proximal transverse flange connected to the longitudinal body and having a slanted surface facing outwardly toward the distal transverse flange to be disposed adjacent an inner surface of the column wall; and a wedge-shaped choke configured to be disposed between the slanted surface of the proximal transverse flange and the inner surface of the column wall. 
         [0013]    In some embodiments, the modular structural components include a truss. The connecting mechanisms include a beam connected to the column, the beam having a plurality of key slots; and a plurality of protrusions at an end of the truss to be received into the key slots of the beam. 
         [0014]    In some embodiments, the modular structural components include a truss. The connecting mechanisms include a beam connected to the column, a holder base mounted to the beam, and a pair of spaced holder supports extending from the holder base to receive the truss therebetween, the pair of spaced holder supports each including an aperture for a fastener to pass therethrough to fasten the truss to the pair of spaced holder supports. 
         [0015]    In specific embodiments, the column is formed by two column segments connected by a column extension sleeve. The modular structural components include a beam, and the beam is formed by two beam segments connected by a beam extension sleeve. 
         [0016]    These and other aspects of the invention are described in further detail below and shown in the accompanying drawings. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0017]      FIG. 1  is a schematic perspective view of a typical modular frame building system. 
           [0018]      FIG. 2  is an exploded schematic perspective view of a column to base connecting mechanism. 
           [0019]      FIG. 3  is a schematic perspective view of a column to beam connecting mechanism. 
           [0020]      FIG. 4  is a schematic perspective view of another column to beam connecting mechanism. 
           [0021]      FIG. 5  is a schematic perspective view of another column to beam connecting mechanism. 
           [0022]      FIG. 6  is a schematic perspective view of a transitional column sleeve for column to column connecting mechanism. 
           [0023]      FIG. 7  is a schematic perspective view of another transitional column sleeve for column to column connecting mechanism. 
           [0024]      FIG. 8  is a schematic perspective view of a truss/beam to column connecting mechanism. 
           [0025]      FIG. 9  shows schematic views of (a) the truss/beam to column connecting mechanism of  FIG. 8 ; (b) a sectional view along A-A; and (c) a sectional view along B-B. 
           [0026]      FIG. 10  shows additional schematic views of (a) the truss/beam to column connecting mechanism of  FIG. 8 ; (b) a sectional view along A-A; and (c) a sectional view along B-B. 
           [0027]      FIG. 11  shows (a) a schematic perspective view of a truss to column connecting mechanism; and (b) a side view thereof. 
           [0028]      FIG. 12  is a schematic perspective view of another truss to column connecting mechanism. 
           [0029]      FIG. 13  is a schematic view of a truss to beam connecting mechanism. 
           [0030]      FIG. 14  is a schematic view of another truss to beam connecting mechanism. 
           [0031]      FIG. 15  is a schematic perspective view of a column. 
           [0032]      FIG. 16  is a schematic perspective view of an extension sleeve for a beam or column. 
           [0033]      FIG. 17  shows (a) a schematic perspective view of an end of a beam or column; and (b) a sectional view along A-A thereof. 
           [0034]      FIG. 18  shows (a) a left side view, (b) a front view, and (c) a right side view of a threaded bolt. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0035]      FIG. 1  is a schematic perspective view of a typical modular frame building system. The building is divided into multiple one-story modules that are connected by various connecting mechanisms. The frame members include columns  10 , beams  12 , trusses  14 , and a base  16 . The frame members are connected by column to base connections, column to beam connections, truss/beam to column connections, truss to column connections, and truss to beam connections, as described below. 
         [0036]    1. Column to Base Connection 
         [0037]      FIG. 2  is an exploded schematic perspective view of a column to base connecting mechanism. As shown in  FIG. 2 , a footing anchor bolt  22  having a threaded end  24 , a washer  26 , and a nut  28  are used to mount a column sleeve  30  to the base  16 . The column sleeve  30  is a transitional part between a hollow column  10  and the base  16 . The column and the column sleeve  30  have matching shapes, while the outer dimension of the column sleeve  30  is slightly smaller than the inner dimension of the column. The column sleeve  30  desirably has an adjusting hole  32  with a sufficient size for receiving the anchor bolt  22  to allow position adjustment of the column sleeve  30 . An adjusting ring  34  is provided between the column  10  and the base  16  to adjust the height of the column from the base  16 . The adjusting ring  34  is selected from a set of adjusting rings, each having different heights in order to provide a desired elevation of the column relative to the base  16 . For example, the adjusting rings  34  can have standards heights of ⅛″, ¼″, ½″, ¾′, 1″, and the like. After the column is positioned on the adjusting ring  34 , a threaded column bolt or fastener is inserted through the column into a fixing hole  36  of the column sleeve  30  to fasten the column to the column sleeve  30 . The column sleeve  30  may include an integrally formed or built-in nut at the fixing hole  36  or a threaded fixing hole to threadingly receive the threaded column bolt. The base  16  can be the ground level flooring for the first story. The base  16  can also be an upper floor and a different anchor bolt similar to a regular bolt can be used instead. 
         [0038]    2. Column to Beam Connection 
         [0039]      FIG. 3  is a schematic perspective view of a column to beam connecting mechanism according to one embodiment of the invention. A column connecting member  40  is welded to the end of a beam  42  which is configured to rest on a slot at the top of a column (see slot  212  of column  210  in  FIG. 15 ). The column connecting member  40  includes a longitudinal body  44  and a transverse flange  46  at the end of the longitudinal body  44 . The transverse flange  46  has an inclined or slanted inner surface  48  facing the beam  42 . The transverse flange  46  is to be placed inside the hollow column facing the inner surface of the column wall. A wedge-shaped choke  50  cooperates with the inclined inner surface  48  of the column connecting member  40  to secure the connection between the beam  42  and the column. The wedge-shaped choke  50  includes a slot  52  to receive the longitudinal body  44  of the column connecting member  40 . 
         [0040]      FIG. 4  is a schematic perspective view of another column to beam connecting mechanism. As seen in  FIG. 4 , a pair of L-shaped beam holding bars  60  are welded to the inside of a hollow beam  62 . The L-shaped bars  60  have holes  64  that match corresponding holes  66  on a column  68 . Threaded bolts  70  are used to fasten the column  68  to the L-shaped bars  60  through the holes  64 ,  66 . The holes  64  of the L-shaped bars  60  can be threaded or can include integrally formed nuts facing inwardly. The L-shaped bars  60  may be disposed slightly inward from the end of the beam  62 , as seen in  FIG. 4 . 
         [0041]      FIG. 5  is a schematic perspective view of another column to beam connecting mechanism. The connecting mechanism is a tongue-in-groove connection wherein the tongue  80  is provided on the beam  82  (e.g., mounted to the interior of the hollow beam) and the groove  84  is provided on a member or block  86  fastened to the side of the column  88  using bolts  90  or other fasteners. Of course, the tongue  80  and groove  84  can be switched between the beam  82  and the column  88 . 
         [0042]      FIG. 6  is a schematic perspective view of a transitional column sleeve for column to column connecting mechanism. A transitional column sleeve can be used to connect an upper floor column with a lower floor column. In  FIG. 6 , the transitional column sleeve  100  has a shape generally matching shapes of the upper and lower columns and has a size slightly smaller than sizes of the upper and lower columns to fit inside hollow interiors of the upper and lower columns. Fasteners are used to fasten at least one of the upper and lower columns to the transitional column sleeve  100 . The transitional column sleeve  100  may include fixing holes  102  with integrally formed or built-in nuts  104  to be threadingly connected by fasteners to fasten the column transitional sleeve  100  to one or both of the upper and lower columns. In addition, the transitional column sleeve  100  may include slots  106  that correspond to the slots of the column(s) (see slots  212  of column  210  in  FIG. 15 ). Such a transitional column sleeve  100  is compatible with the column to beam connection of  FIG. 3 . 
         [0043]      FIG. 7  is a schematic perspective view of another transitional column sleeve for column to column connecting mechanism. In  FIG. 7 , the transitional column sleeve  110  has a shape generally matching shapes of the upper and lower columns and has a size slightly smaller than sizes of the upper and lower columns to fit inside hollow interiors of the upper and lower columns. Fasteners are used to fasten at least one of the upper and lower columns to the transitional column sleeve  110 . The transitional column sleeve  110  may include fixing holes  112  with integrally formed or built-in nuts  114  to be threadingly connected by fasteners to fasten the column transitional sleeve  110  to one or both of the upper and lower columns. In addition, the transitional column sleeve  110  may include a plurality of holes  116  matching openings in at least one of the upper and lower columns (see holes  66  of column  68  in  FIG. 4 ). Such a transitional column sleeve  110  is compatible with the column to beam connections of  FIGS. 4 and 5 . Although square columns are illustrated in these examples, columns have other shapes such as circular and rectangular shapes may be used. 
         [0044]    3. Truss/Beam to Column Connection 
         [0045]      FIG. 8  is a schematic perspective view of a truss/beam to column connecting mechanism for connecting a truss or a beam to a column. A multi-purpose column cap  120  is placed on top of the column and includes holes  122  for attaching a truss/beam holder  124  at different locations, including the side and the corner. The holder  124  includes a holder base  126  and a pair of spaced holder supports  128  extending from the holder base  126  to receive the truss or beam therebetween. The pair of spaced holder supports  128  each include an aperture  130  for a fastener to pass therethrough to fasten the truss or beam to the pair of spaced holder supports  128 . The holder base  126  may include a built-in nut  134  which is fastened by a bolt  136  and a washer  138  to the column cap  120  at one of the holes  122 .  FIG. 9  shows one position of the holder  124  at a side of the column cap  120 .  FIG. 9  shows schematic views of (a) the truss/beam to column connecting mechanism of  FIG. 8 ; (b) a cross-sectional view along A-A; and (c) a cross-sectional view along B-B.  FIG. 10  shows another position of the holder  124  at a corner of the column cap  120 .  FIG. 10  shows additional schematic views of (a) the truss/beam to column connecting mechanism of  FIG. 8 ; (b) a cross-sectional view along A-A; and (c) a cross-sectional view along B-B. The holder  124  can be attached to the column cap  120  at any of the holes  122  to provide the desired location and orientation. The column cap  120  provides a versatile connection mechanism for the truss or beam to the top of the column. 
         [0046]    4. Truss to Column Connection 
         [0047]      FIG. 11  shows (a) a schematic perspective view of a truss to column connecting mechanism; and (b) a side view thereof. At this upper end truss connection, a column connecting member  150  is welded to the truss  152  which is configured to rest on a slot at the top of a column (see slots  212  of column  210  in  FIG. 15 ). The column connecting member  150  includes a longitudinal body  153  extending across and received into the slot of the column, and a transverse flange or choke holding end  154  connected to the longitudinal body  153  and having a slanted surface  156  facing inwardly toward the truss  152 . A wedge-shaped choke  158  cooperates with the inclined inner surface  156  of the column connecting member  150  and is disposed between the slanted surface  156  and the column wall to secure the connection between the truss  152  and the column. 
         [0048]      FIG. 12  is a schematic perspective view of another truss to column connecting mechanism. At this lower end truss connection, a column connecting member  160  is welded to the truss  162  which is configured to rest on a slot  164  at the top of a column  166 . The column connecting member  160  includes a longitudinal body  168  extending across and received into the slot  164  of the column  166 , a distal transverse flange  170  connected to the longitudinal body  168  to be disposed at an outer surface of the column wall, and a proximal transverse flange  172  connected to the longitudinal body  168  and having a slanted surface  174  facing outwardly toward the distal transverse flange  170  to be disposed adjacent an inner surface of the column wall. A wedge-shaped choke  176  is configured to be disposed between the slanted surface  174  of the proximal transverse flange  172  and the inner surface of the column wall. 
         [0049]    The connecting mechanisms of  FIGS. 11 and 12  provide alternatives to the use of the column cap  12  of  FIGS. 8-10  when the use of the column cap  12  is not possible or desirable for any reason. The angles of the connecting members in  FIGS. 11 and 12  should follow the slope of the truss. Some typical angles can be modularized to standardize production. 
         [0050]    5. Truss to Beam Connection 
         [0051]      FIG. 13  is a schematic view of a truss to beam connecting mechanism. A truss  180  has at an end thereof protrusions or tabs  182  that are slidably coupled into key slots  184  provided on a beam  186 . 
         [0052]      FIG. 14  is a schematic view of another truss to beam connecting mechanism. A truss holder  190  is fastened to the beam  192  for connecting with a truss  194 . The beam  192  is connected to a column. The truss holder  190  includes a holder base  196  mounted to the beam  192 , and a pair of spaced holder supports  198  extending from the holder base  196  to receive the truss  194  therebetween. The pair of spaced holder supports  198  each include an aperture  200  for a fastener to pass therethrough to fasten the truss  194  to the pair of spaced holder supports  198 . The holder base  196  may include a threaded nipple  202  to be screwed into a threaded hole of the beam  192  for mounting to the beam  192 . 
         [0053]      FIG. 15  is a schematic perspective view of a column  210  having four slots  212  at an upper end thereof. The length of the column  210  is equal to the distance from the bottom of the column to the top of the beam that needs to be supported. Some typical lengths can be chosen. The length of the slots  212  should match the beam height or truss height. Accordingly, some standard lengths can be used. 
         [0054]      FIG. 16  is a schematic perspective view of an extension sleeve  220  for a beam or column. The extension sleeve  220  is slightly smaller in cross section than the beams or columns and fits partially inside the beams or columns. The holes  222  are provided for coupling to the beams or columns using fasteners. The holes  222  may be threaded or built-in nuts may be provided at the holes  222 . The extension sleeve  220  is connected between two beams or two columns to form a longer beam or column. Using the extension sleeve  220 , all beams or columns can be modularized into a few sizes. 
         [0055]      FIG. 17(   a ) shows a schematic perspective view of an end of a beam or column  240  for connecting to the extension sleeve  220  of  FIG. 16 . The openings  242  are configured to matching the holes  222  of the extension sleeve  220  for coupling by fasteners.  FIG. 17(   b ) shows a sectional view along A-A of  FIG. 17(   a ) of only the left and right openings  242 , omitting the sections with the top and bottom holes  242 . 
         [0056]      FIG. 18  shows (a) a left side view, (b) a front view, and (c) a right side view of a threaded bolt  250 . The threaded bolt  250  extends through each of the openings  242  of the beam or column  240  and the holes  222  of the extension sleeve  220  to connect the beam or column  240  to the extension sleeve  220 . 
         [0057]    For the connecting mechanisms employing chokes in  FIGS. 3 ,  11 , and  12 , the slanted surfaces on the transverse flanges serving as choke holding wings are important for holding the chokes and keeping them from coming loose. The chokes preferably have extra length so that after they are hammered tight against the surfaces, the narrow ends of the chokes can be bent against the transverse flanges to lock the chokes to the transverse flanges permanently. 
         [0058]    Finally, a frame construction procedure utilizing the connection techniques described above is used to construct a modular frame. First, the base footing is poured with the footing anchor bolts  22  in place for the columns. The column sleeve  30  is installed over the footing on top of the anchor bolt  22 . The next step is to adjust the position of the column sleeve  30 , level the column sleeve  20 , and to fix the column sleeve  30  in place using the washer  26  and nut  28 . After all column sleeves  30  are fixed, a level is used to mark out the base line on each column sleeve  30 . Adjusting rings  34  are selected for the column sleeves  30  to adjust the bottom of the corresponding columns to the desired elevation or base line height. The columns  10  are positioned over the column sleeves  30  to rest on top of the adjusting rings  34  or the footing if there is no need for an adjusting ring. At this time, the holes on the columns should line up with the fixing holes  36  of the column sleeves  30  and fasteners are used to fasten the columns  10  to the respective column sleeves  30 . 
         [0059]    The next step is to connect the beams  12  to the columns  10  using any of the connecting mechanisms described above (see, e.g.,  FIGS. 3-5 ). Transitional column sleeves  100  or  110  are placed on top of the columns (as well as the beam to column connections), while ensuring that the distance between the fixing holes on the transitional column sleeve and the edge of the top of the lower column will match the holes on the bottom end of the upper column to be placed thereupon. The next step is to fix the beams to the columns by the chosen connecting mechanisms to make permanent connections (e.g., by hammering tight the choke  52  in  FIG. 3 ). Floors are constructed on top of the installed beams  12 . 
         [0060]    To add another story, upper columns are placed on top of the transitional column sleeves  100  or  110  and fastened together. Beams are connected to the upper columns and then permanently fixed. Floors are constructed on top of the installed beams. These steps are repeated until the top story is constructed and the roof level is reached. 
         [0061]    For roof installation, the connection mechanism utilizing the column cap  120  and truss/beam holders  124  of  FIGS. 8-10 , the mechanism utilizing the connecting member  150  of  FIG. 11 , the connection mechanism using the connecting member  160  of  FIG. 12 , the mechanism using protrusions  182  and key slots  184  of  FIG. 13 , and/or the mechanism using the truss holders  190  of  FIG. 14  can be used. The top beams and/or roof trusses are then fixed to complete the frame construction. 
         [0062]    Although preferred embodiments of this invention have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.