CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from Israel Patent Application No. 279244 filed on December 6, 2020, which is expressly incorporated herein by reference in its entirety.

FIELD

Embodiments disclosed herein relate in general to prefabricated construction techniques and more specifically to improved prefabricated modules for use in construction of buildings.

BACKGROUND

There have been many prior proposals for constructing buildings from prefabricated units. In some proposals, panels may be prefabricated and transported to a site for assembly into a building. The transport of the panels may be reasonably straightforward, but the assembly on the building site may involve a considerable amount of labour. In other proposals, an entire building may be prefabricated and transported, often with some difficulty. Another option may be to make a building from several prefabricated three-dimensional modules and assemble the modules on site, but in that case both transport and assembly tend to be time-consuming and expensive.

Many types of prefabricated modules were commercialized in the 1950's. Many of these suffered from quality problems. Some of these problems were tied to low building standards, problems that may have existed in traditional building but were exacerbated in the prefabricated modules. Since then, many countries have found that cheap labour disincentivizes technological progress in prefabrication of modules and improvement of building methods and systems. However, recent improvement of building standards, lack of cheap labour due to political or pandemic conditions, and an ever-increasing demand to shorten construction periods have created a new interest and desire for improved prefabrication of modules. SUMMARY

Various embodiments described below aim to address shortcomings of the known art described above and provide further advantages and improvements. Embodiments described below relate to prefabricated construction modules and to methods and systems to construct buildings from the modules.

It is anticipated that the ability to construct the modules from very readily available components, construct them simultaneously at numerous off-site factories/workshops, transport the modules to site, position them, weld them together, and pour the concrete at the building site may save at least 35% of the building time as compared to the fastest commercially available methods and systems. The limitations of how many modules may be transported from each workshop to the building site may be limited by local regulations, road conditions such as bridges along the transport path etc.

It is anticipated that the improved building method may provide for buildings that are not only cost effective to build but may also last longer than conventional buildings, i.e., about 70-80 years instead of about 50-60 years.

As used herein, the term “modules” refers to prefabricated structures used as components of buildings. The terms cement and concrete may be used interchangeably. Concrete that is said to be poured may be assumed to be in a slurry state.

In some embodiments, a building module includes: two walls and a floor, wherein each of the two walls includes a wall metal lattice partially enclosed by a plurality of panels on either side of the wall, wherein the floor includes a floor metal lattice covered on one side by a plurality of panels, wherein the wall metal lattices and floor metal lattice are fixedly attached to one another, and wherein the module is configured for pouring concrete therein to fill the metal lattices and create a contiguous concrete fill within the walls and floor.

In some embodiments, the building module further includes a ceiling, wherein the ceiling includes a ceiling metal lattice covered on one side by a plurality of panels, wherein the wall metal lattices and ceiling metal lattice are fixedly attached to one another, wherein the ceiling module is configured for pouring concrete therein to fill the metal lattices and create a contiguous concrete fill with the concrete fill of the walls. In some embodiments, the building module further includes one or two additional walls. In some embodiments, the metal lattices comprise a plurality of metal L-shaped beams fixedly joined together with connector beams, with metal mesh grids laid therebetween. In some embodiments, the panels are formed from oriented strand board (OSB).

In some embodiments, a method of construction of a building includes constructing multiple of the modules as described above; transporting the constructed modules to a site; placing and fixedly attaching the constructed modules one on top of the other and/or side by side; and filling the walls and floors of the constructed modules with concrete.

According to one aspect, a building module is provided including: thin long boards and thin short boards (both referred to herein as “panels”); multiple L-shaped beams including at least two interwall floor L-shaped beams, at least two interwall ceiling L-shaped beams, at least two long vertical external L-shaped wall-beams, at least two long vertical internal L-shaped wall-beams, at least two short vertical external L-shaped wall-beams and at least two short vertical internal L- shaped wall-beams, wherein the at least two short vertical external L-shaped wall-beams and at least two short vertical internal L-shaped wall-beams are each affixed to an interwall floor beam and an interwall ceiling beam; wherein: each long vertical external wall-beam and short vertical external wall-beam, and each long vertical internal wall-beam and short vertical internal wall-beam attached to same interwall floor beam and interwall ceiling beam, are spaced apart and configured to allow engaging a thin long board with the long vertical external wall-beams; engaging a thin long board with the long vertical internal wall-beams, engaging a thin short board with the short vertical external wall-beams, engaging a thin short board with the short vertical internal wall-beams, making a wall between the thin long board engaged with the long vertical external wall-beams and the thin short board engaged with the short vertical external wall-beams, and making a wall between the thin long board engaged with the long vertical internal wall-beams and the thin short board engaged with the short vertical internal wall-beams, and affixing each long vertical external wall-beam and long vertical internal wall-beam, short vertical external wall-beam, and short vertical internal wallbeam to the same in adjacent building modules.

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

In order to understand the disclosure and to see how it may be carried out in practice, embodiments will now be described, by way of non-limiting example only, with reference to the accompanying figures. In the figures, identical and similar structures, elements, or parts thereof that appear in more than one figure are generally labelled with the same or similar references in the figures in which they appear. Dimensions of components and features shown in the figures are chosen primarily for convenience and clarity of presentation and are not necessarily to scale. In the attached figures:

FIGS. 1A and IB schematically show a building module in an elevated perspective view according to some embodiments;

FIG. 1C is a side-view of a cross section of a wall of a module according to some embodiments;

FIG. ID is a side-view of a cross section of a floor or ceiling of a module according to some embodiments;

FIG. IE shows a cross section of a side-view of a wall 102 and ceiling 108 intersection according to some embodiments;

FIG. IF shows a metal lattice of a module with extended portions according to some embodiments;

FIG. 1G shows a metal lattice of a module with extended portions attached to construction piles according to some embodiments;

FIG. 1H shows a corner unit for attaching adjacent walls in a module according to some embodiments; and

FIGS. 2A and 2B are illustrative drawings showing examples of buildings constructed using a building module according to some embodiments.

DETAILED DESCRIPTION

Embodiments described below relate to modules and to methods and systems to construct buildings from the modules. The principles and operation of a method and/or system according to exemplary embodiments may be better understood with reference to the drawings and accompanying descriptions. Before explaining at least one embodiment in detail, it is to be understood that the disclosure is not limited in its application to the details set forth in the following description or exemplified by the Examples. The disclosure is capable of being practiced or carried out in various ways. Also, the phraseology and terminology employed herein is for the purpose of description and exemplification and does not limit the scope of the disclosure.

FIG. 1 schematically shows a building module 100, in a perspective view. Building module 100 includes a wall section 102, a floor section 106, and a ceiling section 108. Building module 100 may be used as a room in a building 200 (FIGS. 2A and 2B). Module 100 as shown may be prefabricated or prebuilt in a factory and then transported to a site for inclusion as part of building 200. It should be appreciated that the prefabricated nature of module 100 may allow for greater accuracy and efficiency in construction and, once on site, faster and more cost-effective construction of building 200. Module 100 as shown in FIGS. 1A and IB is a metal and wood structure that is filled with concrete once in position on site. It should be appreciated that module 100 therefore takes its final form as well as full weight once on site. Module 100 as illustrated herein does not include any openings for windows or doors, but it should be appreciated that these may typically be added in the factory before transport to site. Fixed metal joins as described herein may be made, for example, by welding.

As shown in FIG. 1A, module 100 may be provided with a ceiling section 108. In some embodiments, as shown in FIG. IB, a module 100’ may be provided without a ceiling section 108. Modules 100 and 100’ may be sized according to the needs of the building where modules 100 and/or 100’ are to be installed including changes to the dimensions of walls 102, floor 106 and/or ceiling 108.

Metal beams, mesh grids, and other metal pieces may be fixedly attached to one another to form a metal lattice 109 within walls 102, floor 106 and ceiling 108. The metal lattice 109 described herein may be altered and other arrangements of metal lattice may be appropriate for module 100.

Walls 102 may have the structure shown in FIG. 1C, which is a side-view of a cross section of wall 102. Wall 102 may be formed from metal L-shaped beams 110 fixedly joined together with connector beams 112, with metal mesh grids 114 laid therebetween. L-shaped beams 110 placed alongside one another form a T-shape. Alternatively, T-shaped metal beams may be used. Dual L- shaped beams 110 attached together (T-shape) and attached by a connector beam 112 may be said to form an H-beam. Panels 116-1 and 116-2 are attached on either side of metal lattice 109 to contain concrete poured therein. In some embodiments, panels 116 remain attached to module 100 following the pouring of concrete therein. In some embodiments, panels 116 may be formed from oriented strand board (OSB). Once so constructed, a concrete fill 118 may be filled into the volume defined by the beams 122, 124 and panels 116 to thereby surround metal lattice 109 to create a reinforced concrete wall.

Floor 106 and ceiling 108 may have the structure shown in FIG. ID, which is a side-view of a cross section of floor 106 or ceiling 108. Floor 106 or ceiling 108 may include a floor/ceiling metal lattice 109 formed from metal L-shaped beams 110 fixedly joined together with connector beams 112, with metal mesh grids 114 laid therebetween. L-shaped beams 110 placed alongside one another form a T-shape. Alternatively, T-shaped metal beams may be used. Panel 116 is attached on the bottom side of metal lattice 109 to contain concrete poured therein. In some embodiments, panel 116 may remain attached to module 100 following the pouring of concrete therein. In some embodiments, panel 116 may be formed from OSB. Once so constructed, a concrete fill 118 may be filled into the volume defined by the beams 122, 124 and panel 116 to thereby surround metal lattice 109 to create a reinforced concrete floor 106 or ceiling 108.

Although shown and described separately, it should be appreciated that walls 102 and floor 106, and walls 102 and ceiling 108 are interconnected to form a contiguous module 100. FIG. IE is a side-view of a wall 102 and ceiling 108 intersection showing, for example, mesh grids 114 overlapping in the area of intersection. As shown, a wall panel 116-1 on an interior surface of module 100 is shorter than a panel 116-2 on an exterior surface of module 100 to accommodate the intersection with a panel 116-3 of ceiling 108. FIG. IE also shows a contiguous poured concrete filling 118 within ceiling 108 and wall 102 around metal lattice 109.

In some embodiments, as shown in FIG IF, the metal lattice 109 may feature extended portions 111 that extend beyond the external surfaces of module 100. These extended portions 111 may be fixedly attached to the metal lattices 109 of one or more adjacent modules 100 such as when multiple modules 100 are used together for forming a building 200 (FIGS. 2A and 2B). In some embodiments, extended portions 111 may be formed as part of the prefabrication process of modules 100, 100’ (i.e., in the workshop/ factory). In some embodiments, extended portions may include rebar. As shown in FIG. 1G, extended portions may extend downwards from modules 100, 100’ such that modules 100, 100’ may be fixedly attached to construction piles 117 for holding a ground level module 100, 100’ in position.

As shown in FIG. 1H, module 100 may include adjacent walls 102-1 and 102-2 that, in some embodiments, are fixedly attached to one another using a corner unit 104. The illustrated portions of walls 102-1 and 102-2 are identical to each other but in general may have different dimensions and/or components as required by the building plans. Long vertical external wall-beams 120a, and long vertical internal wall-beam 120c can be affixed to L-beams 110 in adjacent walls 102.

In some embodiments, corner unit 104 may include long vertical external wall-beams 120e, 120f, and long vertical internal wall-beams 120g, 120h. All of four long vertical wall-beams 120e, 120f, 120g, 120h have essentially identical dimensions. These beams are L-shaped and are affixed to vertical wall-beams in walls 102-1 and 102-2.

Corner unit 104 may further include long corner beam 120i and several metal bands 170 which are affixed at one end 172 to the long corner beam 120i, and at another end 174 to the long vertical external wall-beams 120e, 120f, at regular intervals along the lengths of the long corner beam 120i, and the long vertical external wall-beams 120e, 120f. Metal bands 170 are an important reinforcement to the corner unit 104 strength. Typically, 3 to 7 metal bands are used for each corner unit 104.

FIGS. 2A and 2B are illustrative drawings showing examples of buildings constructed using a building module according to some embodiments. FIG. 2A shows construction of a building 200 using module 100, and FIG. 2B shows construction of a building 200’ using a combination of modules 100 and 100’. According to aspects of the disclosure, a multitude of building modules 100 may be manufactured off-site, transported to a building site, coupled to each other side by side and one atop the other, and filled with cement to quickly build rooms and storeys.

As shown in FIG. 2A, when multiple modules 100 are stacked one on top of the other to form a building. Each floor and ceiling, except for the floor of the first floor and ceiling of the last storey, include a "double layer" of floor 106 and ceiling 108. For example, where one "layer" of ceiling 108 belongs to a first storey, and another "layer" of floor 106 belongs to a second storey above the first storey.

As shown in FIG. 2B, when multiple modules 100’ are stacked one on top of the other to form a building, each floor 106 belongs to a first storey and also forms the ceiling of a second storey below the first storey. To compensate for the lack of an additional layer on the ground floor, additional interwall-beams can be added to create another layer. Such an additional layer may be especially important where there is need for good heat insulation of the floor, or where there is very wet climate that can cause the ground under the building to swell.

An array of first building modules may be affixed in series to each other to form part of a storey. Storeys may also include additional walls 102 and may thus include corner units 104. As shown above, the modules 100, 100’ may include extended portions 111 to facilitate connection of adjacent modules 100, 100’.

In large modules 100, 100’ additional beams 110 may be used to help support the load on the structure, in particular proximal to the centres of the lengths of the beams 110, thus preventing sag of the interwall-beams 110.

The first storey modules may further include metal rods that are part of the foundations of the building and extend from the ground under the storey and into the walls.

Decorative stones may be added to the external wall of the modules. It should be appreciated that the L-beams help to hold the stones in place, thus enormously improving the resistance of the building's facade to wear and tear, including preventing shedding of stones which can be both difficult to repair and dangerous in ordinary buildings. The wall areas opposite the external vertical beams can be covered by a different decorative feature such as paint. The ends of the stones that are not held by the L-beams can be held with bolts that engage the edges and penetrate through the panels and into the concrete and engage with the concrete.

The assembly of the modules and the building can be done in various ways and order of construction. It is considered best to pour the concrete for the walls after all the modules are in place in the building. Concrete typically includes plasticizers, which tend to separate from the concrete while it sets, if the concrete is exposed to a gradient of strains. However, the above system and method may alleviate this problem and provide for stronger and more uniform concrete, which is important to prevent cracks and material breaches. Walls may easily be added in between adjacent modules to create separate rooms. Typically, 5-10 first building modules may be affixed to each other for each room.

Doorframes, window- frames, electricity boxes, heating manifolds and piping etc., may be added to the modules before pouring concrete into the modules in accordance with the building plans. The modular design greatly eases the process of servicing installed wiring and piping since the basic module components are all exactly known and not hidden behind pillars, beams etc.

In some embodiments, the beams, meshes (nets) and bands may be made of construction steel. In some embodiments, panels 116 may be made of compressed wood. In some embodiments, the walls may include concrete. The materials and dimensions of the components in the disclosed building modules may vary within ranges dictated by the structural strength requirements of local regulations, the sizes of the buildings and rooms therein, the geological local features etc.

In some embodiments, the vertical metal rods of corner units 204 may have a diameter of at least 10mm, more preferably at least 12mm. In some embodiments, panels 116 may be made of compressed wood and should be at least 2cm thick, more preferably at least 2.5 cm thick. In some embodiments, the bands of corner modules 204 may be made of metal and be at least 2mm thick. In some embodiments, T-beams made from the fused interwall L beams and H-beams made from the fused vertical beams may have the standard thicknesses of such building beams. In some embodiments, the metal mesh grid may be at least of 6mm thickness and made of metal.

In some embodiments, plaster may be laid over the interior sides of the walls. In some embodiments, insulation materials and layers can be added to inside the walls before the pouring of the concrete. In some embodiments, the width of the walls is typically 20cm-40cm wide, depending upon the intended use of the rooms.

In some embodiments, the floor may include a metal plate of about 4mm thickness affixed to the interwall-beams, and tiling/ boards/and/or polyurea layer can be placed thereon. In some embodiments, polyurea may be added to the walls for heat insulation. In some embodiments, to further strengthen the walls, in between the metal mesh grids of building modules in adjacent storeys, metal rods may be inserted into the unset concrete. In some embodiments, the rods are typically about 60cm long and are placed about every 20 cm along the walls.

In some embodiments, a method for building a first module is provided that includes:

1) Laying on a floor of a metal workshop/factory or other suitable workshop multiple interwall L-shaped beams of suitable dimensions and at a suitable distance from each other. The distance is typically about 60 cm from each double L-beam (T-beam), but the dimensions and the distance may depend upon the plan/s of the room.

2) A metal mesh grid may now be placed above the attached L-shaped beams (T-beams), parallel to the ground. The metal mesh grid is cut to have a width essentially same as the distance between the outermost L beams. The metal mesh grid may have holes sized 20*20cm, and the mesh have a diameter of 5mm. The metal mesh grid may be welded at roughly a height of 6 cm above ground to the insides of the attached L-beams. Following attachment of vertical connector beams, a second mesh grid is attached and cut to size and a second layer of attached L-beams is attached thereto to complete a metal lattice.

3) A panel (thin board) may now be inserted below the structure and is cut to have a width essentially the same as the distance between the external-most L-beams.

5) Vertical metal lattices may be created using the steps above to create the walls of the module.

6) Panels may be attached on the outer sides of the walls and on the inner sides of the walls leaving spaces into which concrete may be poured.

7) In some embodiments, a celling may now be constructed in the same manner on top of the walls.

8) Another panel (thin board) may be held essentially parallel to the ground and is attached to the bottom of the ceiling metal lattice.

9) In some embodiments, plaster boards may be attached with bolts or screws to the thin boards (panels).

10) In some embodiments, the electricity, water, sewage and communication systems and piping/wiring are installed within the module.

11) In some embodiments, modules and optionally corner units may be welded together to form welded room modules.

12) In some embodiments, windows and doors may be installed into the welded room modules, using metal frames of about 3 mm thickness spanning the distance between L- beams to form rooms without the concrete.

13) The rooms without the concrete may be transported to the building site and may be positioned according to the construction plans.

14) After all the rooms without concrete are assembled and approved by a building engineer or similar individual, concrete may be poured into the empty spaces in the ceilings, walls, and floors, such as by using a crane and a concrete pump. Finishes (ceramics, paint, fixtures, etc.) may then be applied to the building. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Although suitable methods and materials are described below, methods and materials similar or equivalent to those described herein can be used in the practice of the present embodiments. In case of conflict, the patent specification, including definitions, will control. All materials, methods, and examples are illustrative only and are not intended to to be limiting.

One skilled in the art will appreciate that the features described above may vary in shape and structure from those shown in the figures but fulfill the same or similar purpose such as to essentially achieve the same results.

It is appreciated that certain features of the disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination or as suitable in any other described embodiment of the disclosure. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments unless the embodiment is inoperative without those elements.

Although the disclosure has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

In the description and claims of the present application, each of the verbs, "comprise," "include" and "have" and conjugates thereof, are used to indicate that the object or objects of the verb are not necessarily a complete listing of components, elements or parts of the subject or subjects of the verb.

In the discussion unless otherwise stated, adjectives such as “substantially” modify a condition or relationship characteristic of a feature or features of an embodiment. The terms are understood to mean that the condition or characteristic is defined to within tolerances that are acceptable for operation of the embodiment for an application for which it is intended.

Unless otherwise indicated, the word “or” in the specification and claims is considered to be the inclusive “or” rather than the exclusive or, and indicates at least one of, or any combination of, items it conjoins. Descriptions of embodiments in the present application are provided by way of example and are not intended to limit the scope. The described embodiments comprise different features, not all of which are required in all embodiments. Some embodiments utilize only some of the features or possible combinations of the features. Variations of embodiments of that are described, and embodiments comprising different combinations of features noted in the described embodiments, will occur to persons of the art.