Abstract:
The invention relates to a pre-fabricated module for living accommodation, comprising: 
     a base;
 
two left and right side façades;
 
a front façade comprising a entrance door;
 
a rear window façade;
 
and a roof element.
 
wherein the base, the façades and the roof element are all made of a structure comprising a layer of projected phenolic resin with embedded electrical ducting. In a particular mode of embodiment, the pre-fabricated module comprises a utility shaft having its own access door on the front face and passing through said module from bottom to top, enabling the interconnection with two other modules respectively arranged beneath and above said pre-fabricated module.

Description:
[0001]    This application is a Continuation of PCT Application no. PCT/EP2012/001148, which was filed on Mar. 14, 2012, and which is herein incorporated by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to the field of construction and more specifically a prefabricated module for residential use which is particularly light and economical. 
       BACKGROUND 
       [0003]    The demographic development faced by all Western societies as well as developping countries gives a particularly critical focus to the issue of providing a House to everybody. 
         [0004]    It is therefore extremely important to meet the growing needs in this field and to achieve technical solutions being easy to carry out and economic. 
         [0005]    The technique of prefabricated construction provides a first solution to this problem since buildings for residential use can be fastly constructed. 
         [0006]    However, such technique requires highly specialized skill to be used, thus making its use quite confidential. It would be necessary to be able to develop more this technique so that everybody is given the opportunity to use it for the purpose of solving the problem of Housing. 
         [0007]    It is therefore highly desirable to achieve a fully prefabricated housing unit, allowing multiple configurations, which would simultaneously provide comfort, lightness, durability and, of course, economy in its use. 
         [0008]    Such a wish shows to be critical even out of the crucial context—even dramatic in some circumstances—of the housing problem known by nowadays societies. Indeed, when considering for instance the field of tourism that is being developped in many regions and even in developping countries, it can be seen that even in such lighter context, it is also desirable to have a light, functional and durable solution to provide cost-effective solutions to public housing temporary, and particularly small and economic hotel architectures can be easily deployed on site with minimal impact on the natural environment. 
         [0009]    Such are the problems that are solved by the present invention. 
       SUMMARY 
       [0010]    It is a first object of the present invention to achieve a prefabricated module, especially for residential use or even hotel, which is particularly functional, durable and economical to install. 
         [0011]    It is another object of the present invention to achieve a prefabricated module that can be easily deployed by combination of small functional modules, both in the vertical and in the horizontal directions, thus facilitating the deployens the different modules for the purpose of arranging a more complex residential structure or even an hotel. 
         [0012]    It is still another object of the present invention to achieve a prefabricated module incorporating all the modern features and facilities to ensure the comfort of an occupant, and at a particularly low cost. 
         [0013]    The invention achieves these objects by means of a prefabricated module for residential use having a base and walls which are made exclusively by means of a layer of phenolic resin proposed embedding electrical conduit. 
         [0014]    In a particular embodiment, the prefabricated module further comprises a service shaft or conduit having its own access door opening outside, the service shaft crossing the whole module from the bottom to the top and enabling the interconnection with two other modules, respectively disposed on and under said prefabricated module 
         [0015]    In a particular embodiment, the base comprises two plates, respectively bottom and top which are separated by re-splits and further comprising a cutout for the passage of the service shaft. In the top plate composing the base, there is embedded a shower tray top plate within the thickness of the phenolic resin composing the floor of the module. 
         [0016]    In one particular embodiment, the service shaft has two side portions, respectively right and left, and a rear wall. An inner boundary element also composed of phenolic material, is used for achieving a delimitation within the inner volume of the service shaft of two subvolumes, respectively dedicated to the water flows and to the high/low voltage electrical distribution system. 
         [0017]    In a particular embodiment, the inner element has a profile showing three sections, respectively horizontal, vertical and horizontal section for the purpose accomodating a heating/air conditioning unit. 
         [0018]    In a particular embodiment, the syphon of the shower is directly offset within the internal volume of the service shaft for the purpose of facilitating visiting and maintenance from the outside access door of the service shaft. 
         [0019]    Preferably the module is associated with a frame having a base composed of modules of the type “HN” and having four posts having a “L” profile, each post comprising at the top one bracket for supporting the base of a upper prefabricated module, thus allowing the stacking of different prefabricated modules. 
         [0020]    The frame can be made of metal or extruded polyester resin. 
         [0021]    In a particular embodiment, the facades comprise, within their internal structure, a decorative photographic layer. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]    Other features, objects and advantages of the invention will become apparent upon reading the following description and drawings below, given by way of non-limiting examples. In the accompanying drawings: 
           [0023]      FIG. 1   a  is a first perspective view of the base element of an embodiment of the prefabricated module. 
           [0024]      FIG. 1   b  is a second perspective view of the base element of an embodiment of the prefabricated module. 
           [0025]      FIG. 2   a  shows a lateral façade view (left) of an embodiment of the prefabricated module. 
           [0026]      FIG. 2   b  illustrates another example of a lateral façade view highlighting the arrangement of the power supply electric wires within the internal volume of the service shaft. 
           [0027]      FIG. 3  is a lateral right façade view of an embodiment of the prefabricated module 
           [0028]      FIGS. 4   a  and  4   b  illustrate two perspective view of the roof element of one embodiment of the prefabricated module. 
           [0029]      FIG. 5  is a front perspective view of an embodiment of the prefabricated module. 
           [0030]      FIG. 6  is a rear perspective view of an embodiment of the prefabricated module. 
           [0031]      FIG. 7  illustrates the technical service shaft that incorporates most of the technical facilities of the prefabricated module. 
           [0032]      FIG. 8  shows the installation of adorn shower in the prefabricated module. 
           [0033]      FIG. 9  shows the structure of the walls panels of one embodiment of the prefabricated module. 
           [0034]      FIG. 10  illustrates a perspective view showing a vertical stacking of prefabricated modules according to the invention. 
           [0035]      FIG. 11  shows a plan of dimensions of a embodiment of a prefabricated module. 
           [0036]      FIG. 12  is a top view of the roof of an embodiment of the prefabricated module. 
           [0037]      FIG. 13  is a side elevation of a façade structure for vertical stacking of different modules. 
           [0038]      FIG. 14  shows the section A-A′ in  FIG. 11 . 
           [0039]      FIG. 15  illustrates a front elevation of the B. 
           [0040]      FIG. 16  illustrates a front elevation of the B′ in a situation with the structure for the vertical stack of modules. 
           [0041]      FIG. 17  shows the front window of prefabricated module. 
           [0042]      FIG. 18  shows the cross section BB′ of an embodiment of the prefabricated module. 
           [0043]      FIG. 19  shows the section CC′ of an embodiment of the prefabricated module. 
           [0044]      FIG. 20  shows the section DD′ of an embodiment of the prefabricated module. 
           [0045]      FIG. 21  illustrates the stacking of four prefabricated modules so as to realize a a more complex structure, Ground+3. 
       
    
    
     DESCRIPTION 
       [0046]    There is now described one particular embodiment of a highly functional, lightweight and inexpensive to manufacture and maintain prefabricated, module. 
         [0047]    The following description will be particularly suited to the production of a prefabricated module for tourism, offering its occupants all the modern features and comfort that one may expect from a modern hotel and which, moreover, has exceptional durability even in very difficult exploitation conditions. 
         [0048]    Clearly, one may adapt the description of the prefabricated module to the achievement of an T1 type apartment or a larger apartment by combining different modules, as described below, so as to achieve more complex architectural structures. 
         [0049]    The prefabricated module which is described below has a particularly economic manufacturing process and shows a light structure. 
         [0050]    For this purpose, it is exclusively made from seven components, described below, all resulting from the same manufacturing process and, preferably, made exclusively from panels composed of phenolic polyester resin. 
         [0051]    Such material is known in the manufacturing process of ships and aircraft since it allows the manufacturing of thin and resistant shells. 
         [0052]    The inventors have discovered that it is possible to spray much thicker layers of phenolic resin for the purpose of embedding, within the same panel, electrical conduit and thus achieve, in a single manufacturing a complete prefabricated façade being particularly light (despite the thickness of the layer of phenolic resin), economic and easy to implement. 
         [0053]    There is one proposed a new structure for a prefabricated module which is exclusively realized from such material and that then leads to the possibility of producing a lightweight, economical unit, particularly resistant and durable. 
         [0054]      FIG. 9  particularly illustrates a first embodiment of the common structure of seven elements which will be described below in more detail, based on the use of a projected resin. 
         [0055]    It is seen that the structure comprises a succession of elementary layers so as to realize a lightweight and durable wall or panel. Starting from the inside of the wall to the outside, there is a first layer  91  of fibreglass, such as of the mat Gel Coat type which is well-known to the skilled man versed in the construction of ships and aircrafts, and an aluminium structure net  92  which, and this is particularly advantageous, will be the only metallic structural element of the panel, then a sprayed resin having a high thickness, up to 10 cm. At the top of the panel, one arranges a further aluminium structure net  94 , then covered with one or more layers of Gelcoat mat for completing the final aspect of the panel. 
         [0056]    Phénolyque resin used in this particular embodiment provides a significant advantage in that its mechanical characteristics does not diminish when exposed to high temperatures, such as in case of fire within the module. 
         [0057]    The resulting wall shows outstanding features, particularly in terms of sound and thermal insulation, but also in terms of fire behavior. One may nonetheless optionally combines the wall with an additional fireproof panel, such as a M2 panel being surfaced and laminated or similar, which will provide additional fire protection, which will improve the already existing fire protection resulting from the use of the phenolic resin layer  93 . 
         [0058]    As this is shown in  FIG. 9 , the structure allows the realization of a plate or a façade or elements which can serve for the realization of all the internal parts of an economic, lightweight and durable prefabricated module which, and this is far from negligible, is fully compliant with standards for hotel establishments open to the public. 
         [0059]    One can furthermore decorate the outside panel wall surface with an additional layer allowing photograph inclusion of a material type wood, marble, stone etc. . . . . 
         [0060]    As an alternative, and in a second embodiment (not shown in the figure), the projected foam resin can be replaced by an expanding foam under vacuum injected between two layers of resin, and which is glued. One can also obtain, when using a phenol based foam with or any material showing equivalent mechanical and fire protection characteristics, a panel having high mechanical strength and complying with the European legislation requirements, providing good fire resistance and which do not release toxic fumes which might be harmful to the health of the occupants of the module. 
         [0061]    These panels can be made in many ways, hand made or by means of industrial production, according to choice. 
         [0062]    In a third embodiment, each panel is produced with gelcoat (2 sides, inner skin and outer skin), which receive between them, expanded foam with ceramic fire resistance sheet increasing the fire resistance level. Within the expanded foam there is embedded a structure of extruded resin, having double volume serving for technical passages (low voltage or high voltage) distributing technical services in the composed module, forming perimeter belt for the ceiling, the side walls and the floor, in high or low level in module height, connecting the utility or service shaft with all parts of the finished module. 
         [0063]    Different assembling inserts made of extruded resin are disposed inside of the panels in order to permit screwing when mounting or dismounting the housing module on different operating sites. These panels are made airtight by means of gel coat resin, also completing the aesthetic finish. The expanding foam can be made on the basis of Phenol, but can also be replaced by panels made up of alveolar membranes in resin, or the polyurethane foam injected by vacuum suction. 
         [0064]    More specifically, the method described below can be used for producing a panel of this type which will advantageously be used for partitioning the habitation module. 
         [0065]    For this purpose, there is arranged a mold defining the panel on the bottom and sides (like a drawer), in which one disposes gel-coat finishing façade and a ceramic fire resistance sheet, with pultrusion resin structure, receiving all technical passages, with all spare parts assembly items such as resin inserts for screwing and or reinforcement. On this arrangement a plastic membrane is set defining a volume having an inlet for injecting the expanding foam and an outlet for connection to a suction device. In this way, by plugging the vacuum suction, one can inject under vacuum the expanding foam that fills the interstices and the internal volume of the panel. One then completes the whole by a gelcoat membrane ensuring the hermetic character of the panel and completing the aesthetic finish. 
         [0066]    It is now described the use of such a panel or element for the achievement of a prefabricated module having, such as illustrated in  FIG. 1   a,  a base  10  having a bottom plate  11  and a top plate  12 , both made by means the structure described above in connection with  FIG. 9 . The two plates  1  and  12  are separated by two re-split  13  and  14 —also based on the structure, and defining cavities between the two plates. 
         [0067]    As seen in  FIG. 1   a,  but also on  FIG. 1   b  illustrating another perspective view of the floor element showing a bottom plate  11 , the upper plate having a recessed shower tray  15  embedded in the thickness of phenolic resin, and further comprising a plurality of apertures for flow of water, including a drain port for the receiver  16  and a drain orifice  17  for a sink. 
         [0068]    It should be noted that, in a particular embodiment, the shower can be covered with a cover so as to restore the flatness of the ground for the case where the shower embedded space is not required, for instance when the occupant of prefabricated module would not wish to use the corresponding surface for a wash room. 
         [0069]    As can also be seen, and will be described in more detail below, the upper and lower plates have a cutout disposed on the side of the front door for receiving a vertical service shaft extending from bottom to the top of the prefabricated module, and which will be described in more detail below. Generally speaking, all water and electricity conduits lead to the volume delimited by such cut, as illustrated with the drain tube  18  of the shower, so that all equipments and technical devices can take place within the single service shaft of the prefabricated module. In a particular embodiment, even the shower drain is arranged within the volume delimited by the service shaft so as to allow maintenance operations directly from outside the module. 
         [0070]      FIG. 2   a  shows a view of a façade or a left side panel  20  of an embodiment of the prefabricated module. As noted above, the second element is realized by means of sprayed phenolic resin, having a thickness which is sufficient to, firstly, ensure the rigidity of the wall and, secondly, for allowing embedding within the resin of all the electrical conduit for the power supply of electrical outlets, switches and other connectors. 
         [0071]    The panel  20  has some reliefs—such as the re-split wall  22 —can be used for partitioning and delimiting, as appropriate, spaces on the wall and further includes in its lower part a console  23  having the profile of a shoe for being inserted between the lower plate  11  and upper plate  12  of the base member of  FIG. 1 . The console  23  and ensures both the bonding of the base element with the left side façade and also the squareness of the different constitutive elements composing the floor of the prefabricated module. 
         [0072]    The left side wall of the prefabricated module can embed prefabricated furniture, such as a sink  25 , a wall bed  26 , and various connectors (telephone, electricity, Ethernet) and switches—for example  27  and  28 —and electrical sockets  29 . 
         [0073]    As was mentioned previously, electrical sheathing distribution of small high-current power is embedded within the phenolic resin, thus achieving functionality, lightness and safety. 
         [0074]      FIG. 2   b  shows another example of a perspective view of the left side wall highlighting the detail of the console  23  and also the arrival of electrical conductors  21  (with their appropriate end connectors, eg standardized) in the volume of technical shaft that is accessible from outside. Electric conductors disposed on the other side are used for the power supply of the shutter of the front panel. 
         [0075]      FIG. 2  illustrates a view of the left side wall of an embodiment of the prefabricated module. 
         [0076]      FIG. 3  illustrates a perspective view of a façade or a right side wall  30  of an embodiment of a prefabricated module. The right side wall  30 , made from sprayed phenolic resin also comprises a bracket  33  having the shape of a shoe and serving for the bonding of upper and lower plates  11  of the base  12 . This facade has all plugs and connectors for installing a kitchenette with imprint  32  for a fridge and a cupboard  31 . Drowned in the phenolic resin are located the different electrical conduits for the distribution of high and low voltage, including the introduction of a flat TV  34  and its power outlets— 35  electric and aerial socket  36 , the switches (such as switch  37 ) and different electrical plugs, in particular  38  and  39 . 
         [0077]      FIG. 4  illustrates the roof element which may be mounted and glued on the upper portions of four sides of the module. The roof  40  can have, if appropriate, a cutout  38  corresponding to the parallelepiped volume of the technical service shaft for the purpose of allowing connection with another prefabricated module located above the considered module. In the absence of such an upper module, the roof element comprises a cover  40  (not shown) for covering the cutout  38  and the service shaft. 
         [0078]    As noted, the roof element  40  is also based on a sandwich structure consisting of sprayed phenolic resin so that the weight of the roof is particularly light. 
         [0079]      FIG. 4   b  highlights more clearly the internal structure of the roof element  40 , which shows that it is combined with a false ceiling in the shape of a plate  41  made of sprayed phenolic resin, including the various conduits for electric lights. A double fold in the false ceiling  42  defines on the side of the front window, a space for receiving the shutter device. On the other side, the false ceiling also shows a cut corresponding to the volume of the technical shaft extending from top to bottom of the prefabricated module. 
         [0080]      FIG. 5  is a front perspective view of an embodiment of the prefabricated module, where one can see the roof element  40  with its cutting corresponding to the section of the service shaft, doors and facades  50  and right side  30 . As already seen in this perspective, the front door—and this is a particularly advantageous element, has two doors, including the front and a door designed to allow access from the outside, the volume corresponding to the service shaft. This will result in a space savings since all sensitive equipment, requiring maintenance, can be accessed from outside. 
         [0081]      FIG. 6  is a rear perspective view of one embodiment of the prefabricated module wherein one sees, in a manner similar to above, the roof element  40 , and the two sides left side window  60  and  20 . 
         [0082]    It is described with reference to  FIG. 6  the service shaft  70  which provides all the essential features and facilities of prefabricated module and, as we said, is zo particularly accessible. 
         [0083]    The service shaft  70  consists of two vertical plates  71  and  72 , extending from the bottom to the top of the prefabricated module and having two interior volumes delimited by means of an intermediate element comprising three plate sections  73 ,  74  and  75  respectively vertical, horizontal and vertical. 
         [0084]    It follows that the sheath has two technical areas or volumes, the first volume (left) is particularly slender at the top and wide at its bottom part. Instead, the second volume (right) is particularly slender in its lower and wider in its upper part. 
         [0085]    The left volume is assigned to the water drainage—cold water, wastewater,—while the right volume is dedicated exclusively to high and low voltage. 
         [0086]    It should be noted that walls  71 - 75  of the service shaft  70  are also made up thanks to the sandwich structure described above made of phenolic resin illustrated in  FIG. 9 . Therefore, one can take advantage of a service shaft having a same structure than the other parts of the module, and which can be easily glued to those and which comply to the fire requirements. Once glued, the rear panel composing the technical shaft corresponds to one wall of the washroom of the module, and the right panel  71  completes the side wall of the corridor behind the door of the same module. 
         [0087]    As seen in  FIG. 5 , and this is a particularly advantageous element for the maintenance of the module, the service shaft  70  has its own front door so that any intervention on functional elements of the module is direct from the outside the prefabricated module. 
         [0088]    In a particular embodiment, the technical shaft includes, within its “drainage” volume, a water inlet hose  77  comprising in the lower and upper parts, connectors allowiung the connexion of the technical shafts of different modules, and a stopcock  87 . One also finds the wastewater discharges  78  (connected to a toilet advantageously fixed with low costs on the other side of the rear wall of the service shaft) and sewage  79  and, very advantageously, the trap  86  the shower tray  15  which is thus deported within the volume of the service shaft thanks to a large diameter pipe allowing the water flow from the shower tray down to the trap. It should be noted that the rear wall of the technique used to define the habitation volume inside the prefabricated cabin module and also used to support a toilet and communicating directly with the service shaft. 
         [0089]    The right volume has, meanwhile, a heating/air conditioning  76  taking place on the horizontal section  74  of the intermediate member  73 - 74 - 75 . On the other side of the wall  71 , all the control elements of the electrical components are located, including a main circuit breaker, branch circuit breakers of  82  various switches  83  (central lighting) and a convector heating and air conditioning running  85  in cooperation with the air conditioning unit/heater  76 . The various organs are placed directly at the entrance to the interior of the prefabricated module, and thus communicate directly with the service shaft since it is the same partition or wall  71  which ensures the delimitation. 
         [0090]    As can be seen, this is an arrangement is extremely convenient since the technique provides sheath along the boundary of the interior (via the wall  71  and rear wall), the delineation of two volumes completely disjoint respectively assigned to the liquid flows and electricity wires. 
         [0091]      FIG. 8  shows how one can add an additional boundary to separate the bedroom from the rest of the volume of the bathroom, with a shower screen structure  80  particularly economical and easy to install. As seen in this figure, it is well delimited, very economical, a functional bathroom especially since the shower tray is embedded within the base  12  during the manufacturing process and one of the walls (the front left in  FIG. 8 ) can predispose the facilities of the bathroom. It thus suffices to add the complex element  80 , preferably comprising the door to the bathroom so as to complete the final volume of the bathroom. 
         [0092]      FIG. 10  illustrates a perspective view of the structure allowing a vertical deployment of modules according to one embodiment. 
         [0093]    For this purpose, there is arranged a base consisting of four metallic “HN” type elements composing a base  100  on which one can position the prefabricated module. In a particular embodiment, two metallic elements—a length  101  and a width  102 —are welded during the manufacturing process in factory and arranged for allowing bolting the two halves of the base on the installation site. The four corners of the base  100 , one arranges four posts  120  with a “L” profile having in their upper portion a bracket  130  for supporting another structure identical to the one illustrated in  FIG. 10 , so as to allow the vertical stacking of prefabricated modules. 
         [0094]    In a particular embodiment, the “L” profile posts are arranged to provide the shortest part of the “L” to the front and rear faces of the prefabricated module so as to facilitate release of a lower module once it is in place in a vertical structure. 
         [0095]    In a particular embodiment, the frame  100  is made of extruded polyester resin to further reduce the weight of the structure. 
         [0096]    As seen, the prefabricated module provides easy regarding the deployment “vertical” and can, at will, replace a module with another as needed. One can even imagine the organization of a complex in which they come, as necessary, come position specific modules (eg providing services for people with disabilities) and which could use the operator the complex. 
         [0097]    The “horizontal” deployment of prefabricated modules according to the invention is also extremely easy as simply position as modules next to each other to have either individual units or more spacious apartments with different parts such as we see illustrated in  FIG. 11 , which shows a dimensioned drawing. 
         [0098]    In a particular embodiment, the facade/walls  20  and  30  may be equipped with a door allowing communication between two modules located one beside the other and thus expanding the surface offered to occupants of the modules. 
         [0099]    The module allows great flexibility, allowing the occupants to enlarge the surface according to the needs and resources. 
         [0100]      FIG. 12  and following show views, sections and elevations of prefabricated module in order to illustrate the flexibility and the ergonomy of the module. 
         [0101]    It is seen in particular in  FIG. 13  the cooperation of prefabricated module with the base  100  and the posts so that the stack of modules to achieve a structure of type Ground+3, as shown in  FIG. 21 . 
         [0102]      FIGS. 14 and 15  respectively illustrate a section A-A′ in  FIG. 11  and an elevation of the facade B.  16  illustrates a front elevation of the B′ in a situation with the structure for the vertical stacking of modules.  FIG. 17  shows the front window of prefabricated module.  FIG. 18  shows the cross section BB′ of an embodiment of the prefabricated module.  FIG. 19  shows the section CC′ of an embodiment of the prefabricated module.  FIG. 20  shows the section DD′ of an embodiment of the prefabricated module. 
         [0103]    The structure is easily disassembled and transported, each panel being very light and being embedded with all technical facilities of the housing unit, in particular the washroom. Thus, by disassembling the front façade comprising the entrance door, one can completely change the electrical system, including the air conditioning system. The module will be easily removable and can be reinstalled as desired by various successive locations. 
         [0104]    They can very easily be using in the hospitality industry, allowing their installation and removal as needed.