Patent Publication Number: US-2021189719-A1

Title: Modular system for constructing a timber-frame building

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     See Application Data Sheet. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     THE NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT 
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     INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC OR AS A TEXT FILE VIA THE OFFICE ELECTRONIC FILING SYSTEM (EFS-WEB) 
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     STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINT INVENTOR 
     Not applicable. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to the field of timber-framed building construction. More specifically, the invention relates to a modular system for constructing a timber-framed building. 
     2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98. 
     In this field, buildings are generally formed through the assembly of a plurality of timber-framed modules. The modules generally comprise a plurality of horizontal beams and joists and a plurality of studs defining a plurality of frames which can be assembled vertically to form a lower floor and an upper floor. In addition, modules are assembled horizontally, by delimiting a wall of the building, between two modules. 
     For sufficient mechanical strength both horizontally and vertically, the beams are generally made of solid wood secured in each frame of each module, with a bracing means external to the studs, which conventionally comprises at least one panel and/or joist, or an external or high beam connecting said studs. When assembling modules, the walls between two horizontally assembled modules are found to have a significant thickness which penalizes the internal surface of the building. Thus, the implementation of conventional modules is often criticized for having bearing walls that are too thick. Indeed, a classic composition is based on 120×45 mm studs, for example with a shear panel on the outside of the wall, and in the center, a double wall resulting at best, as an example, in the thicknesses of two panels of 12 mm each, two 120 mm studs, associated with a clearance of 10 mm and a 0.1 mm vapor barrier, for a total excluding lining of 274 mm wall thickness. 
     Unless otherwise stated, the terms “external” and “internal” refer to the inside of the module concerned. 
     One objective of this invention is to provide a modular construction system wherein the wall thickness between two modules assembled horizontally is significantly reduced, while improving the mechanical properties of horizontal and vertical strength of the modular system. 
     Another objective of the invention consists in proposing a modular system allowing the design of a timber-framed building with a floor of great three-dimensional rigidity. 
     To achieve this, a modular timber-framed building construction system is proposed comprising a plurality of timber-framed modules of rectangular parallelepipedal section consisting of a series of full height vertical studs, connected in pairs by at least two horizontal joists, of which at least two timber-framed modules assembled horizontally while delimiting a wall between said modules and at least two timber-framed modules assembled vertically, with at least one wall stud being provided among said vertical studs. 
     BRIEF SUMMARY OF THE INVENTION 
     According to the invention, at least said horizontally adjacent module wall studs are offset and overlap, at least partially with respect to each other, and the studs of an upper module rest on the studs of a lower module, directly or indirectly through a layer of non-compressible material, such as a metal sheet, a sealing film, or any other non-compressible material with the exception of a horizontal wood layer with fibers. 
     Advantageously, the arrangement of the studs and more specifically of the wall studs makes it possible to limit the thickness of the wall as a function of the extent of their overlap, without affecting the mechanical properties of the wall since the number of studs is not decreased. 
     According to other aspects taken alone or combined according to any technically feasible combinations: 
     The system comprises at least one stud bracing means allowing said overlapping, among which at least one wall reinforcement is preferably provided, and said wall reinforcement is internal to said wall stud of the corresponding module; and/or 
     The stud bracing means comprise at least one internal shear panel and/or one or more joists forming, preferably a frame with the stud, delimiting each module; and/or 
     The system comprises at least one insulator between two modules assembled horizontally, the insulator being arranged between the outside of said stud of a module, and the outside of a shear panel of the second module; and/or 
     The system comprises at least one insulator between two modules assembled horizontally, the insulator being placed in an empty space between the two shear panels of the horizontally adjacent modules; and/or 
     The system comprises at least one post for each of two modules arranged horizontally, associated with at least one beam secured to the end of the post, and said post is positioned in an at least partial recess of said beam and/or said beam is positioned in an at least partial recess of said post; and/or 
     The system comprises at least one post for each of the two modules arranged horizontally, and said posts are offset and overlapping, at least partially, with respect to each other; and/or 
     The system comprises a spacing between, on the one hand, said stud and/or said bracing means of a first module, and, on the other hand, said stud and/or said bracing means of a second module arranged horizontally to the first module; and/or 
     The system comprises a securing means between, on the one hand, said stud and/or said bracing means a first module and, on the other hand, said stud and/or said bracing means of a second module arranged horizontally to the first module. 
     Another subject matter of the invention relates to a timber-framed building comprising at least one modular system according to the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The invention will be further detailed by the description of non-limiting embodiments, and on the basis of the appended figures. 
         FIG. 1  is a perspective view of a modular system according to a preferred embodiment of the invention. 
         FIG. 2  is a perspective view similar to that of  FIG. 1 , further illustrating panels. 
         FIG. 3  is a sectional view of a system according to a variant similar to that of  FIG. 1 . 
         FIG. 4  is a perspective view of part of a timber-framed building. 
         FIGS. 5A to 5D  illustrate elevation and partial perspective views of a different arrangement of walls including the insertion of studs or increased section or posts which can be found in particular points. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     This invention relates to a modular construction system  1 . The modular system  1  according to the invention makes it possible to construct a timber-framed building  2 . 
     The modular system  1  according to the invention comprises at least three wooden framework modules  3 A,  3 B,  3 C of rectangular parallelepipedal section, and each composed of at least two vertical studs  4 , connected by at least two horizontal joists  5 , preferably a series of studs  4  thus connected by joists  5 . 
     The module also preferably comprises posts  6  and beams  7 . The assembly forms a frame making it possible to stiffen building  2  constructed from at least one such modular system  1 . The beams can also be stringers. Beyond the construction of modules  3 A,  3 B,  3 C, the assembly of at least two of them horizontally is provided, namely, in particular, by juxtaposition of two construction modules  3 A and  3 B side by side, and attachment together to form a timber-framed building  2 . 
     Modules  3 A,  3 B, thus assembled, delimit a wall  8  between them. Wall  8  comprises several elements of the timber-framed. A series of full height studs  4  are provided among the elements of the timber-framed in each module  3 A,  3 B,  3 C. In addition, among studs  4  there is at least one, preferably several wall studs  4   a , that forms part of the wall  8 . 
     The studs  4  and posts  6  are pieces of wood with vertical fibers. The studs  4 , preferably, but not necessarily, have a smaller section than that of the posts  6 . The posts  6  can be used at the corners and/or individual points, for example, openings and ends of a module  3 A,  3 B,  3 C, and studs  4  can be used between the ends. 
     The joists  5  and the beams  7  are pieces of wood with horizontal fibers. The joists  5  preferably but not necessarily have a smaller section than that of the beams. For example, the joists  5  have a section of approximately 220 by 45 mm. The beams  7  can be used at the corners and at the end of a module  3 A,  3 B and the joists  5  can be used between the ends. Wall reinforcements  5   a  can be provided in the wall  8 . The wall reinforcement can be a top rail and can have a section similar to that of a joist. 
     According to the invention, at least the wall studs  4   a  are offset in a direction parallel to the corresponding wall  8  and overlap, at least partially, in a direction perpendicular to the corresponding wall  8 . In particular, at least the wall studs  4   a  of a first module  3 A are offset with respect to the wall studs  4   a  of a second adjacent module  3 B horizontally to the first module  3 A. In addition, these wall studs  4   a  overlap one another. In other words, the wall studs  4   a  overlap at least partially so as to have an at least partial alignment horizontally. More specifically, when the wall studs  4   s  are observed along the orientation of the wall  8  independently of other construction elements, the nearest wall stud  4   a  at least partially conceals the most distant wall stud  4   a.    
     The horizontally adjacent modules  3 A,  3 B thus form, in particular, a plurality of offset frames which overlap one another at the wall  8 . 
     Advantageously, the arrangement at least of the wall studs  4   a  makes it possible to limit the thickness of the wall  8  depending on the overlap of the studs, without however affecting the mechanical properties of the wall since the number of studs  4  is not, in particular, significantly reduced. 
     The system according to a variant comprises at least one stud bracing means allowing said overlap. In the context of the invention, the “bracing means” is in particular a part making it possible to maintain a gap between the studs  4 , or between a stud and an end or a beam. The absence of a top or bottom rail also allows said overlap. 
     Thus, the invention allows an advantageous arrangement compared to the prior art where bracing means on the outside of the wall studs are provided. These bracing means on the outside, or at the top and/or bottom of the wall studs, do not allow the wall studs to overlap in the prior art, contrary to the subject matter of the invention. 
     More specifically, the bracing means which can be used in the invention consist of elements internal to the wall studs  4   a  or lateral thereto and substantially internal. These elements at least allow to leave a space between the wall studs  4   a  for at least the overlapping of the wall studs  4   a  of the horizontally adjacent module. 
     The bracing means preferably comprise at least one wall reinforcement  5   a  which is internal to said wall stud  4   a  of the corresponding module. The bracing can also be ensured by the beams  7 . 
     According to a variant, the stud  4  bracing means comprise at least one shear panel  9  and/or one or more joists  5 , preferably forming a frame with the studs, delimiting each module. The shear panel  9  can be an oriented strand board panel which can, for example, measure 12 mm thick. 
     Advantageously, this new frame arrangement makes it possible to provide new methods of assembly of modules. In particular, it is possible to provide a securing means between, on the one hand, said wall stud  4   a  and/or said bracing means of a first module  3 A, and, on the other hand, said wall stud  4   a  and/or said bracing means of a second module  3 B arranged horizontally to the first module  3 A. In other words, the arrangement according to the invention makes it possible to provide for the studs of a first module  3 A to be assembled to the studs of a second module  3 B or to the wall of the second module  3 B to ensure assemblies between modules  3 A,  3 B. Advantageously, the overlap of at least the wall studs  4   a  makes it possible to provide an attachment at the overlap, for example by penetrating parts or by gluing means. Another attachment system can be provided. 
     According to one variant, the modular system  1  comprises at least one insulator  10 , in particular one or a plurality of insulating elements, between two horizontally adjacent modules  3 A,  3 B. This insulator  10  is placed between the outside of said wall stud  4   a  of a module  3 A, and the outside of a shear panel  9  of the second module  3 B. In particular, the insulator  10  can be a thermal and/or an acoustic insulating element. The insulation can, for example, measure 40 mm in thickness. It can be in the form by a sheet or a substance to be poured into the wall. 
     More generally, to improve the insulation, in particular the sound insulation, of the building  2 , the system comprises a spacing between, on the one hand, said wall stud  4   a  and/or said bracing means of a first module  3 A, and, on the other hand, said wall stud  4   a  and/or said bracing means of a second module  3 B assembled horizontally to the first module  3 A. In particular, during the construction of building  2 , contact between certain elements of the frameworks of the horizontally adjacent modules is avoided, which greatly improves the sound insulation. More specifically, it could be provided that the wall studs  4   a  of a first module  3 A are not in contact with the wall studs  4   a  and/or the internal shear panel  9  of a second module  3 B. 
     The system also comprises at least two timber-framed modules  3 A,  3 C assembled vertically. The applicant has already proposed a significant improvement in the vertical strength of a timber-framed in application WO 2014/140479 A1. In particular, the studs  4  of an upper module  3 C rest on the studs  4  of a lower module  3 A directly or indirectly, but without the interposition of compressible wood with horizontal fibers. 
     Thus, a layer of non-compressible material, such as a metal sheet, a plastic material film, a vapor barrier film, in particular bituminous, etc. can be interposed between the studs superimposed substantially in the same alignment. 
     The surprising advantage resulting from the invention consisting in an interlocking of the adjacent module wall studs and the vertical hold by direct overlay of the stacked module studs, without interposed compressible material, consists of a synergy of these characteristics, which entails a greatly improved three-dimensional strength for a building  2  with floors. 
     According to one variant, the system comprises at least one corner post  6  or one intermediate post for each of the two modules arranged horizontally, associated to at least one beam  7  secured to a preferably lower end of the post  6 . 
     The posts  6  of adjacent modules  3 A,  3 B can also be offset and overlap, at least partially, in the same way as the wall studs  4   a . This configuration can be illustrated by  FIG. 5A . 
     In one variant, the corner post  6  or the intermediate post is housed in an at least partial recess of said beam  7  and/or said beam  7  is positioned in an at least partial recess of said post  6 . The same arrangement with a joist in the stead and place of a beam  7  can be considered. In particular, the corner posts  6  and the intermediate posts, as the case may be, can be provided along a joist or a beam. In this case, these posts  6  can face one another, being integrated in the low beam  7 , which will be all or in part hollowed out at the location of the post  6 . This configuration can be illustrated by  FIG. 5B . 
     Alternatively or in combination, for example on other posts  6 , the same can be, in whole or in part, hollowed out to fit against the low beam  7 . This configuration can be illustrated by  FIG. 5C . 
     Alternatively, or in combination, for example on other posts  6 , the same can be assembled with a halved joint with the joist or the beam  7 , with partial hollowing out of the post and of the beam or the joist  7 . 
     More specifically, the corner posts  6  or the intermediate posts, as the case may be, can be machined in variable shapes to maintain a sufficient cross-section, while allowing the reduction of the wall  8 . The posts  6  could therefore be assembled one along the other by interlocking shapes. This configuration can be illustrated by  FIG. 5D . 
     The invention further relates to a timber-framed building comprising at least one modular system as described above. 
     The realization of such a timber-framed building  2  includes at least one step of constructing at least three timber-framed modules  3 A,  3 B,  3 C, comprising a series of studs  4  running the full height of said module. At least one wall stud  4   a  is provided among these studs  4 . 
     Then, at least two modules  3 A and  3 B are assembled horizontally by offsetting the wall studs  4   a  in a direction parallel to that of the corresponding wall  8 , while having them overlap, at least partially, in a direction perpendicular to that of the corresponding wall  8 . 
     More specifically, the method is based on a horizontal assembly of the modules  3 A,  3 B by offsetting the wall studs  4   a  relative to one another, in a direction parallel to that of the corresponding wall  8 , while having them overlap, at least partially relative to each other, in a direction perpendicular to that of the corresponding wall  8 . 
     In addition, the method comprises a step of constructing at least one wall  8  comprising said wall studs  4   a.    
     EXAMPLE 
     The walls of the timber-framed modules, obtained according to the invention, comply, in particular, with the DTU 31.2 standard, meaning solid wood studs  4   a  of variable section juxtaposed at regular intervals or not, but often of 30, 40 or 60 cm. 
     These studs  4   a  are braced by a panel  9  (for example, long-strand reconstituted panels, gypsum fiberboards, wood chipboards, etc.). 
     This panel  9  can interchangeably be placed on the outside or inside of the wall  8 , for example, of a living room. 
     The implementation of modules  3 A,  3 B, according to the invention, with studs  4   a  and conventional panels  9 , results in a typical composition, excluding a liner, which may consist of a successive addition of:
         for a first module  3 A:
           a 12 mm thick panel  9 ;   a 120×45 mm (120 mm thick) section stud  4   a;      
           then 10 mm clearance;
           a 10 to 40 mm thick acoustic insulation;   
           then for a second module  3   b:  
           a (120 mm thick) stud  4   a  completely or partially covering the stud of the first module; and   a 12 mm thick panel  9 ;   
               

     This results in a total of 194 mm, excluding a liner, which can be reduced to 154 mm without sound insulation  10 . 
     The wall studs  4   a  can completely cover one another if there is no sound insulation. 
     Advantageously, the arrangement according to the invention makes it possible to integrate insulating materials  10  or lining sheets in the walls  8  without increasing the thickness thereof, but instead by decreasing it. 
     As a consequence, other combinations are possible, for example with thicker studs, conventionally 145 mm or 180 mm in size, preferably with two lining sheets which may measure 15 mm. 
     Likewise, advantageously, the arrangement according to the invention makes it possible to increase the size of the studs  4   a  of the walls  8  without increasing its thickness, but instead by decreasing it. 
     The method of constructing a building, according to the invention, also provides for the stacking of at least two modules  3 A,  3 C so that the respective studs  4  of these modules overlap. 
     More precisely, each stud  4  of the upper module  3 C comes to rest  1  on a stud  4  of a lower module  3 A, this directly, at the very least without the interposition of a compressible element, in particular without the interposition of a wooden element with horizontally-oriented fibers which, in fact, would be compressible. 
     Thus, between these studs, it is possible to interpose a layer of an non-compressible material such as a metal sheet and/or a synthetic or even bituminous material film, or a vapor barrier, for example, in order to create a water-tight barrier.