STATEMENT OF CORRESPONDING APPLICATIONS

This application is based on the Provisional specification filed in relation to New Zealand Patent Application Number 589892, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

The invention herein relates to the structural framing for a modular building assembly system for onsite assembly. Specifically, the present invention relates to provision of hollow profile extrusions and a method of interconnection of same.

BACKGROUND ART

Modular building systems can present a cost-effective alternative to traditional on-site construction methods. Typically a building constructed using a modular system may involve reduced labour time and utilise less highly skilled labour, both of which can reduce costs in comparison with traditional construction methods. Building modules can be used for a wide variety of structures, including (without limitation) residential housing, holiday homes, hotels/motels, mine workers' shelters and other shelters for use in remote areas, warehouses, and commercial offices. Traditional modular building systems ordinarily consist of pre-fabricated and often pre- constructed modules which are assembled on-site by connection in block fashion along the module's straight edges. Such "back-to-back" assembly can raise problems including an inability to effectively align, join and seal multiple modules together. In particular a poor seal can allow moisture, air, and dust infiltration into the completed structure. Other disadvantages can include instability and the possibility of easy separation of one module from another.

A further disadvantage that can arise with traditional modular structures is the restriction on customer design preferences (in relation to structure design and subsequent attachments) which can occur as a result of shipping constraints (i.e. an inability to be taller or wider than standard shipping containers). This can impose limitations in relation to the span length that the structure is capable of supporting, for example. Furthermore, the structure of traditional modules can lead to inefficient use of space during transportation which can add to the transport and handling costs for the modules. Demand continues to increase for modular buildings made from quality pre-fabricated structural components which may be efficiently and accurately assembled at a designated site with flexibility in personal design, optimal strength and aesthetic appeal. It would be an advantage to provide a framing system for modular buildings that improves on existing modular building structural framing systems and interconnecting methods, and which attains assembly efficiency, increases structural stability and accurate alignment of elements, enables universal and multipurpose use of extrusions, reduces the need for specialised labourers and provides increased customer flexibility in structural layout.

It is an object of the present invention to address the foregoing problems or at least to provide the public with a useful choice.

All references, including any patents or patent applications cited in this specification are hereby incorporated by reference. No admission is made that any reference constitutes prior art. The discussion of the references states what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinency of the cited documents. It will be clearly understood that, although a number of prior art publications are referred to herein, this reference does not constitute an admission that any of these documents form part of the common general knowledge in the art, in New Zealand or in any other country.

Throughout this specification, the word "comprise", or variations thereof such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only.

DISCLOSURE OF THE INVENTION

According to one aspect of the present invention there is provided a structural framing element for use with a modular assembly system, the structural framing element configured as a hollow, elongate member having a uniform cross section along its length, wherein the elongate member has four sides configured in a substantially square or

substantially rectangular arrangement, and wherein each side includes at least one concave indentation or at least one convex protrusion. According to another aspect of the present invention there is provided a structural framing element for use with a modular assembly system substantially as described above wherein a pair of opposing sides is configured to include:

• a concave indentation in each side; or · a convex protrusion from each side; or

• a concave indentation on one side and a convex protrusion on the opposing side, wherein each concave indentation is of substantially the same shape and size and each convex protrusion is of substantially the same shape and size, and wherein the shape and size of the concave indentation is complementary to the shape and size of the convex protrusion. Reference to complementary structures throughout this specification should be understood to mean that the structures fit together to form a whole. Specifically, with respect to the indentations and protrusions of the present invention it means that, when a protrusion on a side of one framing element is inserted into an indentation in a side of an adjacent framing element, an outer surface of the protrusion is in contact with an outer surface of the indentation substantially over the entire surface of the indentation. Furthermore it should be understood that corresponding indentations and protrusions are configured such that when inserted as above the sides of the adjacent framing elements are in contact with one another.

Preferably the indentations and/or the protrusions on opposing sides are located directly opposite one another. Preferably the indentations or protrusions on opposing sides are located substantially at the midpoint of each side.

Preferably at least one structural framing element includes a concave indentation on each of the four sides. This embodiment will be referred to as a 'female' hollow extrusion profile.

Preferably at least one structural framing element includes a convex protrusion on each of the four sides. This embodiment will be referred to as a 'male' hollow extrusion profile.

Preferably at least one structural framing element includes a concave indentation on one side and a convex protrusion on another side with the remaining two sides having either:

• a concave indentation on each side; or

• a convex indentation on each side; or · a concave indentation on one side and a convex protrusion on the other side.

This embodiment (in any of the above conformations) will be referred to as a 'combined' hollow extrusion profile. Preferably the structural framing element includes apertures formed at predetermined locations along the concave indentations or convex protrusions. These apertures may be in the form of holes which may be used to attach adjacent structural framing elements by bolting, screwing, riveting (or any other form of attachment as is well known to those skilled in the art) where a convex protrusion on a male (or combined) hollow extrusion profile is inserted into a complementary concave indentation in a female (or combined) hollow extrusion profile. The apertures may be in the form of slots which may be used for fastening supplementary components such as (without limitation) a wall panel or a clamp used to fasten other objects, e.g. pipes. Preferably the structural framing element is extruded.

Preferably the structural framing element is extruded steel.

According to another aspect of the present invention there is provided a structural framing element substantially as described above wherein the interior surfaces of the sides of the hollow elongate member are configured to engage with an industry standard Hollow Section. Preferably the interior surfaces of the sides of the elongate member are configured to contact the outer surfaces of the corresponding sides of an industry standard Hollow Section.

According to another aspect of the present invention there is provided a kitset of structural framing elements substantially as described above, wherein the set of structural elements includes a plurality of structural framing elements, each configured as a hollow, elongate member having a uniform cross section along its length, wherein each elongate member has four sides configured in a substantially square or substantially rectangular arrangement, and wherein each side includes at least one concave indentation or at least one convex protrusion, wherein each concave indentation is of substantially the same shape and size and each convex protrusion is of substantially the same shape and size, and wherein the shape and size of the concave indentation is complementary to the shape and size of the convex protrusion for each structural framing element of the set.

Preferably the kitset of structural framing elements includes at least one female hollow extrusion profile and at least one male hollow extrusion profile.

Preferably the kitset of structural elements also includes at least one combined hollow extrusion profile.

Preferably the kit set includes screws, bolts rivets or other attachment means for attaching adjacent structural framing elements to one another.

Preferably the kit set includes a set of instructions for assembly of a modular frame using the structural framing elements. According to another aspect of the present invention there is provided a method of modular building assembly of a modular frame using two or more structural framing elements as described above wherein a first structural framing element includes a convex protrusion on one side and a second structural framing element includes a complementary concave indentation on one side, the method including the steps of:

• aligning the first and second structural framing elements such that the convex protrusion on the first structural framing element is inserted into the concave indentation on the second structural framing element; and

• fastening the first and second structural framing elements together. According to another aspect of the present invention there is provided a method of modular building assembly of a modular frame using two or more structural framing elements as described above, the method including the steps of:

• inserting an industry standard Hollow Section into the interior of at least one of the

structural framing elements; and · fastening the structural framing element to the industry standard Hollow Section.

The present invention relates to a steel structural framing which may provide an efficient, simple, and accurate assembly system of modular buildings. The extrusions, which have complementary 'female' and 'male' natured profiles, may enable a simple, yet quick and accurate, interconnecting assembly method an result in an improved mechanical seal of structural members.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects of the present invention will become apparent from the ensuing description which is given by way of example only and with reference to the accompanying drawings in which:

Figure 1 shows a cross section of a female hollow extrusion profile according to one

embodiment of the present invention;

Figure 2 shows a cross section of a male hollow extrusion profile according to another embodiment of the present invention; Figure 3a shows a cross section of a combined hollow extrusion profile according to

another embodiment of the present invention; Figure 3b shows a cross section of a combined hollow extrusion profile according to another embodiment of the present invention;

Figure 3c shows a cross section of a combined hollow extrusion profile according to

another embodiment of the present invention; Figure 3d shows a cross section of a combined hollow extrusion profile according to

another embodiment of the present invention;

Figure 4 shows a side view of a female hollow profile according to one embodiment of the present invention;

Figure 5 shows a cross-sectional view of interconnected female, male and combined

hollow profile extrusions according to one embodiment of the present invention;

Figure 6 shows a cross-sectional view of the 'female' extrusion hollow profile of the

embodiment shown in Figure 1 engaged with a Square Hollow Section;

Figure 7 shows a cross-sectional view of the 'male' extrusion hollow profile of the

embodiment shown in Figure 1 engaged with a Square Hollow Section; and Figure 8 shows a cross-sectional view of the 'combined' extrusion hollow profile of the embodiment shown Figure 1 engaged with a Square Hollow Section.

BEST MODES FOR CARRYING OUT THE INVENTION

A structural framing element, in the form of a female hollow extrusion profile according to one embodiment of the present invention is generally indicated by arrow 1 in Figure 1. Figure 1 shows a cross section through the female hollow extrusion profile 1. The female hollow extrusion profile 1 is an elongate member having a uniform cross section (as shown in Figure 1 ) along its length. The female hollow extrusion profile 1 may be extruded in any desirable length according to the requirements of the structure. The female hollow extrusion profile 1 has four sides (2, 3, 4, 5) which are configured in a rectangular arrangement. In other embodiments the four sides may be configured in a square arrangement. Each side (2, 3, 4, 5) of the female hollow extrusion profile 1 includes a concave indentation (6, 7, 8, 9). Each concave indentation is centred about the mid point of one of the sides so that the concave indentations (6 and 8, 7 and 9) on opposing sides (2 and 4, 3 and 5) are opposite one another. Consequently the female hollow extrusion 1 has a symmetrical cross section as seen in Figure 1.

Another structural framing element, in the form of a male hollow extrusion profile according to one embodiment of the present invention is generally indicated by arrow 10 in Figure 2. Figure 2 shows a cross section through the male hollow extrusion profile 10. The male hollow extrusion profile 10 is an elongate member having a uniform cross section (as shown in Figure 2) along its length. The male hollow extrusion profile may be extruded in any desirable length according to the requirements of the structure. The male hollow extrusion profile, generally indicated by arrow 10 in Fig. 2, has four sides (12, 3, 4, 5) which are configured in a rectangular arrangement. In other embodiments the four sides may be configured in a square arrangement. Each side of the male hollow extrusion profile 10 includes a convex protrusion (16, 17, 18, 19). Each convex protrusion is centred about the mid point of one of the sides so that the convex protrusions (16 and 18, 17 and 19) on opposing sides (12 and 14, 13 and 15) are opposite one another. Consequently the male hollow extrusion 10 has a symmetrical cross section as seen in Figure 2.

Another structural framing element, in the form of a combined hollow extrusion profile according to one embodiment of the present invention is generally indicated by arrow 20 in Figure 3a. The combined hollow extrusion profile 20 is an elongate member having a uniform cross section (as shown in Figure 3) along its length. The combined hollow extrusion profile may be extruded in any desirable length according to the requirements of the structure.

The combined hollow extrusion profile 20 has four sides (22, 23, 24, 25) which are configured in a rectangular arrangement. In other embodiments the four sides may be configured in a square arrangement. The combined hollow extrusion profile 20 includes a concave indentation (26) on one side (22) and a convex protrusion (27, 28, 29)) on the remaining sides (23, 24, 25). The concave indentation each convex protrusions is centred about the mid point of the respective side.

Three other embodiments of combined hollow extrusion profiles (30, 40 and 50) are shown in Figures 3b, 3c and 3d. The combined hollow extrusion profiles (30, 40) shown in Figures 3b and 3c have two concave indentations (32, 33 and 42, 44 respectively) and two convex protrusions (34, 35 and 43, 45 respectively). The combined hollow extrusion profile (50) shown in Figure 3d has one convex protrusion (52) and three concave indentations (53, 54, 55).

Figure 4 shows a side view of a side of the female hollow extrusion profile of Figure 1. A series of holes (60) and slots (60a) are drilled along the length of each concave indentation. The holes may be used to screw, bolt, rivet or otherwise attach one hollow profile to another while the slots may be used to attach supplementary panels, clamps or other fixtures as required. Similar series of holes and slots are formed along the length of each concave indentation and /or convex protrusion of each of the hollow extrusion profiles (1 , 10, 20, 30, 40, 50).

The hollow extrusion profiles (1 , 10, 20, 30, 40, 50) may be formed from any suitable material, such as brass, aluminium, stainless steel or reinforcing plastic (among others) using an extrusion process. Each of the hollow extrusion profiles may be formed in any convenient size and length. However, the preferred embodiments the thickness of a side is in the range 1 mm to 20 mm. Similarly, the outer dimension (corner to corner) of preferred rectangular hollow profiles (as shown in Figures 1 - 3) is in the range 50 mm x 50 mm to 500 mm to 500 mm.

Any of the above embodiments may be provided in a set of profiles configured to fit together and to be attached to one another.

A feature of all the above embodiments of the present invention is that, for a given set of profiles, each concave indentation is the same shape and size, and each convex protrusion is the same shape and size. Furthermore, the size and shape of the concave indentations is complementary to that of the convex protrusions, as shown for example in Figure 5. A modular frame, using a set of structural framing elements of the present invention, may be assembled by inserting a convex protrusion on one profile into a concave indentation on an adjacent profile. The two framing elements may then be adjusted (e.g. by sliding one element along the other) to align the holes/slots in each element. The two elements may then be secured by fastening the two framing elements together. Figure 5 shows a series of interconnected profiles, namely a male hollow extrusion profile (61 ) attached to a female hollow extrusion profile (62) attached to a combined hollow extrusion profile (63). The male hollow extrusion profile is attached to the adjacent female hollow extrusion profile by inserting the convex protrusion (64) of the male hollow extrusion profile (61 ) into the concave indentation (65) of the female hollow extrusion profile (62). A threaded bolt (66) is inserted through the aligned holes (see 60 of Figure 4) in each of the profiles to form an attachment between the two profiles. As can be seen in Figure 5, the convex protrusion (64) is complementary to the concave indentation (65), so that the outer surface (67) of the convex protrusion is in contact with the outer surface (68) of the concave indentation over substantially the entire surface of the indentation. Furthermore, the sides (69, 70) of the adjacent profiles are in contact with one another over at least a portion of their length.

A similar arrangement is illustrated in Figure 5 for the connection between the female hollow extrusion profile (62) and the combined hollow extrusion profile (63).

An advantage of the configuration of the structural framing elements according to the present invention and the method of connection using the elements is that adjacent elements may be accurately and simply aligned and secured to create the desired modular structure.

Furthermore, the assembly method does not require the use of highly skilled labour, which may save on labour cost.

The use of complementary protrusions and indentations not only provides quick and accurate alignment of the elements, but may also provide an effective seal against dust, moisture and air flow through the region where the two elements are connected. This seal may be

supplemented in some embodiments by the addition of a sealing means placed between the abutting surfaces of adjacent structural elements. Such a seal may be formed, for example, from a sheet of rubberised material.

Transportation of a set of structural framing elements according to the present invention may also be provided in a space and cost effective manner by arranging the framing elements so that, where ever possible, a convex protrusion is aligned in contact with a concave indentation on an adjacent framing element in the same layer of structural elements, or the layer above or below. With this arrangement a "flat pack" may be filled in a space efficient manner.

Another advantage is that the structural framing elements may be configured to engage with an industry standard Hollow Sections. Such Hollow Sections are commonly used for providing frame members, for example to from a corner of a frame.

Figure 6 shows a cross section through structural framing element in the form of a female hollow extrusion profile (71 ) according to one embodiment of the present invention in which the interior surfaces (72, 73, 74, 75) of the female hollow extrusion profile are configured to contact the outer surfaces (76, 77, 78, 79 respectively) of an industry standard Hollow Section, in the example shown a Square Hollow Section (SHS) generally indicated by arrow 80.

The female hollow extrusion profile (71 ) may be attached to the SHS by a bolt, screw or rivet, in each case with the bolt, screw or rivet insert through a pre-formed hole in the extrusion profile.

Figures 7 and 8 show corresponding arrangements for attaching a male hollow extrusion profile (81 ) and a combined hollow extrusion profile (82) to a SHS (80) respectively. As will be readily understood by a skilled reader similar arrangements may be provided for a structural framing element having substantially rectangular sides where the interior surfaces of the sides are configured to engage with a rectangular Hollow Section (RHS).

The ability to attach a structural framing element according to an embodiment of the present invention to a SHS or RHS may enable quick, effective and accurate alignment of the framing element with a SHS or RHS used in the primary frame of a structure. Additional structural framing elements may be added by attaching them to the structural framing element engaged with the SHS or RHS as outlined above. In this manner up to four orthogonal walls may be formed around the SHS or RHS. Again, attachment of the framing element to the SHS or RHS does not require highly skilled labour, thus potentially saving time and labour cost. This feature may also provide additional design choice over traditional modular systems as the way in which adjacent structural framing elements are selected and interconnected allows for considerable variation.

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof as defined in the appended claims.