Sandwich panel and building module

Abstract

The invention relates to a sandwich panel comprising a metal joist within its outer skin. Also disclosed is a building module which is a sandwich panel comprising a first region providing a roof structural portion of a building, a second region providing a wall structural portion of the building and a third region providing a floor structural portion of the building. The sandwich panel and the building module can be connected together to build a building.

Description

TECHNICAL FIELD

[0001] The present invention relates to sandwich panels and building modules that can be connected together to build a building. BACKGROUND

[0002] The construction industry faces many unique challenges in providing affordable housing. The precast construction sector is attempting to address some of these challenges.

[0003] Prefabricated homes can be built in a factory and then transported to the construction site. The advantage of this approach is that weather and travel of construction professionals does not become a factor in the construction process. One disadvantage is that the design of the prefabricated home is limited by the mode of transport and the route to the construction site, in New Zealand the main mode of transport is by truck, there is also the possibility of transport by rail. These modes of transport limit the width and height of the load to be transported, the length limitation is governed by the size of the vehicle.

[0004] These limitations are usually addressed in one of two ways, either the home is designed to fit exactly onto a truck, these homes are known as “tiny homes”, or the building is designed as multiple modules that are assembled together on site.

[0005] One advantage of prefabricated home designs is that if the design is approved by the Ministry of Business, Innovation and Employment (MBIE) they will grant multiple building consents for the design. This means that building consent applications corresponding to multiple consent documents must be approved by the building consent authority within 10 days.

[0006] Prefabricated home designs manufactured in a factory using traditional components such as timber framed construction can be used as factory manufactured homes or as kits for on site construction. Nookhomes.co.nz offers both forms of transportable housing.

[0007] Factory prefabricated homes using traditional timber framed construction use a large number of components, this results in a lot of labour being required whether the home is assembled on site or in the factory. Transporting assembled homes presents a number of additional challenges.

[0008] Structural insulated panels (SIPs) are a three-layer structure; a core made of a low-density insulation material (such as polyurethane (PUR)) and an outer skin on each side of the core. Therefore, sandwich panels can provide an integrated structural and cladding system. Their strength and light weight mean they can span long distances, making them particularly suitable for wall and roof systems in commercial or industrial buildings; their use in residential buildings is less common. Sandwich panels are typically flat and elongated, although curved sandwich panels can also be used for installation on curved roofs. In use, the elongated side edges are secured to the side edges of adjacent panels. Therefore, the side edges of the panels are often designed with complementary profiles for fastening together, typically using screws.

[0009] As used herein, the term “sandwich panel” refers to a structure comprising three layers: a core made of low-density insulating material and an outer skin on each side of the core. Summary of the Invention

[0010] In a first aspect, the present invention provides a sandwich panel including metal support beams within its outer skin.

[0011] In one embodiment, the sandwich panel includes a thermoplastic skin and an insulating core, wherein the thermoplastic skin is preferably HDPE and the insulating core comprises an insulating material.

[0012] The insulation material may be, for example, a foam material, preferably polyurethane foam or polyethylene foam, or a mycelium composite material, or another suitable insulation material, or a combination thereof.

[0013] In one embodiment, the insulation material comprises polyurethane foam, including polyurethane foam formed using carbon capture technology, and / or polyethylene foam, and / or foam formed from recycled polyethylene terephthalate (PET).

[0014] In one embodiment, the metal support beam is a steel support beam with a cap-shaped profile.

[0015] In one embodiment, the surface of the sandwich panel has a ribbed profile to accommodate the metal support beam.

[0016] In one embodiment, the metal support beams are interconnected by crossbeams fixed between the metal support beams, wherein the crossbeams are preferably 100mm steel cap support beam rivets, which are fixed to the support beams at a center of 600mm.

[0017] In one embodiment, the contours of one side edge are complementary to those of the other side edge, allowing two adjacent modules to be joined together without fasteners. Preferably, one side edge includes a lip, while the other side edge includes a complementary top.

[0018] In a second aspect, the present invention provides a building module, which is a sandwich panel comprising a first region, a second region and a third region, wherein the first region provides a roof structure portion of the building, the second region provides a wall structure portion of the building, and the third region provides a floor structure portion of the building.

[0019] In one embodiment, the first region and the third region of the sandwich panel are the sandwich panel as described in the first aspect.

[0020] In one embodiment, the first and third regions are substantially planar, and the second region is substantially curved into a semicircle, such that the building module is generally U-shaped.

[0021] In one embodiment, the building module has a slot and a hole, the slot extending from the end of the third region toward the second region to accommodate a metal support, and the hole located at the junction of the second region and the third region to accommodate the metal support.

[0022] Thirdly, the present invention provides a method for constructing a sandwich panel, comprising:

[0023] a. Forming the skin of a sandwich panel made of thermoplastic in a rotary oven and allowing the thermoplastic to solidify / cure;

[0024] b. After the skin has solidified / cured, demold the skin and remove at least one end of the sandwich panel;

[0025] c. Insert the metal support beam into the panel;

[0026] d. Fill the board with foam material and harden the foam material; or fill the board with a substrate inoculated with mycelium, and dry or heat the mycelium after the growth period to form a mycelium composite material;

[0027] e. Once the foam material has hardened or formed the mycelium composite material, the excess foam material or mycelium composite material is cut flush with the ends of one or more panels.

[0028] Fourthly, the present invention provides a method for constructing a sandwich panel, comprising:

[0029] a. Forming a skin of a sandwich panel made of thermoplastic in a mold in a rotary oven, and allowing the thermoplastic to solidify / cure;

[0030] b. After the skin has solidified / cured, demold the skin and remove at least one end of the sandwich panel;

[0031] c. Insert the metal support beam into the plate, and insert foam powder into the panel;

[0032] d. Place the panel and one or more removed ends back into the mold; close the mold and rotate it in the oven at low heat to re-thermally bond the one or more removed ends to the panel, and to allow the foam-forming powder to expand into foam within the thermoplastic skin.

[0033] In one embodiment, both ends of the panel are removed in step b).

[0034] Fifthly, the present invention provides a method for constructing a sandwich panel, comprising:

[0035] a. Extruding the outer skin of the sandwich panel made of thermoplastic in an extrusion die;

[0036] b. Optionally, the extruder is heated and bent around a template;

[0037] c. Allows thermoplastics to solidify / cure;

[0038] d. Insert the metal support beam into the panel;

[0039] e. Fill the panel with foam material and harden the foam material; or fill the panel with a substrate inoculated with mycelium, and dry or heat the mycelium after the growth period to form a mycelium composite material;

[0040] f. Once the foam material has hardened or formed the mycelium composite material, the excess foam material or mycelium composite material is cut flush with the ends of one or more panels.

[0041] In one embodiment, the method further includes covering the panel with a thermoplastic end plate using a thermal welding process, optionally the thermoplastic end plate being the end plate removed in step b).

[0042] In one embodiment, the foam material is polyurethane foam or polyethylene foam.

[0043] In a sixth aspect, the present invention provides a method for constructing a sandwich panel, comprising:

[0044] a. Place a metal support beam within a mold on the surface of the sandwich panel, the metal support beam being supported and secured in place by a number of suitable supports, such as isolation plugs or other suitable spacers;

[0045] b. The skin of the sandwich panel is formed in the mold by adding a thermoplastic material, and then the mold is rotated in a rotary oven;

[0046] c. (i) Allowing the thermoplastic to solidify / cure, then demolding the skin with the metal support beams therein, then forming a hole in the panel and filling the panel with insulating material; or

[0047] (ii) The thermoplastic is solidified / cured, and while the thermoplastic skin is still warm, a hole is formed in the panel and the panel is filled with a heat-insulating material. Then, the mold containing the thermoplastic skin is further rotated in the oven at a temperature lower than the melting temperature of the thermoplastic skin, and then the sandwich panel is demolded.

[0048] In one embodiment, the insulation material in step c(ii) is a foam-forming powder containing polyethylene.

[0049] In one embodiment, the metal support beams are interconnected by crossbeams fixed between the metal support beams, wherein the crossbeams are preferably 100mm steel cap support beam rivets, which are fixed to the support beams at a center of 600mm.

[0050] In one embodiment, the sandwich panel includes a first region, a second region, and a third region, the first region and the third region being substantially planar, and the second region being substantially curved into a semicircle, such that the building module is generally U-shaped.

[0051] In one embodiment, the U-shaped panel stands vertically and the foam material or matrix is ​​poured in a controlled manner from the top of the U-shape, thereby filling the entire cavity of the sandwich panel without any gaps.

[0052] In a seventh aspect, the present invention provides a method for constructing a building from a plurality of modules as described in the second aspect, wherein one side edge of the module includes a lip and another side edge of the module includes a complementary top, the method comprising:

[0053] a. Fix the first module in a suitable position relative to the ground;

[0054] b. Align the lip edge of the second module with the complementary top of the first module, and slide the second module onto the first module;

[0055] c. Optionally, the second module is fixed in a suitable position relative to the ground;

[0056] d. Align the lip edge of the third module with the complementary top of the second module, and slide the third module onto the second module;

[0057] e. Repeat steps (c) and (d) until all modules are installed;

[0058] f. Secure the last module in the appropriate position relative to the ground.

[0059] In one embodiment, each second module is fixed in the appropriate position relative to the ground.

[0060] In one embodiment, the building module includes a substantially flat first region and a third region, and a second region that is substantially curved into a semicircle, such that the building module is generally U-shaped. The building module has slots and holes, the slots extending from the end of the third region toward the second region to receive metal supports, and the holes located at the junction of the second and third regions to receive the metal supports. A method of securing the module to the ground includes inserting helical piles into appropriate locations in the ground corresponding to the ends of the slots of each module secured to the ground, thereby forming a first row of helical piles; and inserting helical piles into appropriate locations in the ground corresponding to the holes of each module secured to the ground, thereby forming a second row of helical piles.

[0061] In one embodiment, the method further includes securing a load-bearing beam to each of the first row of helical piles and securing another load-bearing beam to each of the second row of helical piles.

[0062] In one embodiment, the method further includes, prior to step (a), installing a column onto each of the first row of helical piles and securing a beam to the top of the column in the first row of helical piles.

[0063] In one embodiment, the method further includes, after step (f), installing the column onto each of the second row of helical piles and securing the beam to the top of the column in the first row of helical piles. Attached Figure Description

[0064] Figure 1 Cross-sectional views of a sandwich panel according to two preferred embodiments of the present invention are shown.

[0065] Figure 2A A perspective view of a building module according to a preferred embodiment of the present invention is shown.

[0066] Figure 2B A perspective view of a building module according to another preferred embodiment of the present invention is shown.

[0067] Figure 3 It shows including Figure 2B The floor plan of the building structure system of the building module.

[0068] Figure 4A floor plan of a series of building modules according to an embodiment of the present invention is shown.

[0069] Figure 5 It shows Figure 3 The front view of the building structure system shown.

[0070] Figure 6 It shows the result of Figure 2A A 3D model of a building constructed using a 2B building module.

[0071] Figure 7 As shown Figure 3 An exemplary floor plan of the building is shown. Detailed Implementation

[0072] Preferred embodiments of the invention will now be described with reference to the accompanying drawings.

[0073] sandwich panel

[0074] Figure 1 Cross-sectional views of sandwich panels 100 and 200 are shown. Although the widths W of sandwich panels 100 and 200 are 2175 mm and 2000 mm respectively, those skilled in the art will understand that other widths can be chosen. The depths D of sandwich panels 100 and 200 are as follows... Figure 1 As shown, and in this example approximately 260 mm. Although the length L of the sandwich panels 100 and 200 is not in... Figure 1 As shown in the cross-sectional view, but those skilled in the art will understand that sandwich panels are often used as simple support beams, sometimes as cantilever beams, and will understand that known beam design principles can be applied to determine the required depth D of the sandwich panel with reference to a given length L, and vice versa.

[0075] The sandwich panel has cores 110, 210 and thermoplastic skins 120, 220. The lightweight core includes an insulating core comprising a foam material that provides rigidity to the panel. This can be, for example, polyurethane foam, including polyurethane foam formed using carbon capture technology, or polyethylene foam, or foam formed from recycled polyethylene terephthalate (PET). In other embodiments, the lightweight core may include a material such as a mycelial composite material. Mycelial composite materials are formed by growing mycelial spores on a substrate such as wood chips, agricultural byproducts, wool, or yarn.

[0076] The preferred material for the thermoplastic skin is polyethylene, such as high-density polyethylene (HDPE) or linear low-density polyethylene (LLDPE). Thermoplastics offer numerous advantages, including the ease with which they can be molded into simple or complex shapes and can be thermally welded together. In this example, the thickness of the thermoplastic skins 120 and 220 is approximately 5 mm. As is known to those skilled in the art, there are many methods for forming thermoplastic skins, including but not limited to rotational molding, extrusion, and vacuum forming. Advantageously, as is known in the art, flame-retardant additives can be added to the thermoplastic skin.

[0077] In sandwich panels known in the art, the side edges of the panels are typically designed with complementary profiles for securing them together, usually using screws. The sandwich panel of the present invention includes a lip 126 / 226 that is fitted onto the top 127 / 227 of an adjacent sandwich panel.

[0078] The mezzanine panels 100 and 200 include steel support beams 130 and 230. In these examples, the steel support beams 130 and 230 have a profile called MSTophat, typically an inverted V-shape, with a flat top and a protruding flange at the bottom for receiving fasteners. Figure 1 ).exist Figure 1 In the illustrated embodiment, the steel support beam 130 has a depth of 150 mm. Suitable steel support beams are available from suppliers such as Metalcraft Roofing and Steel and Tube Holdings Ltd. One advantage of using commercial steel support beams is that span tables are already available.

[0079] One side of the thermoplastic skins 120, 220 has ribbed profiles 122, 222 to accommodate steel support beams 130, 230. The other side of the thermoplastic skin has flat profiles 124, 224. The spacing J of the steel support beams in the sandwich panels 100, 200 is 290 mm center and 400 mm center, respectively, but those skilled in the art will understand that other spacings are also possible. In a preferred embodiment, the steel support beam has a crossbeam riveted and fixed at a center 600 mm above the support beam. Figure 1 (Not shown in the image). This ensures that the steel support beam is in... Figure 1 The crossbeam is securely inserted into the slot at the indicated position. The crossbeam can be, for example, a 100mm steel cap support.

[0080] Rib profiles 122 and 222 can be referred to as deep rib profiles, wherein the depth of the rib is at least half of the panel depth D (i.e., D2 ≤ 0.5D). In the illustrated embodiment, D2 is 103 mm and D is 260 mm.

[0081] Although inserts 130 and 230 are formed of steel, aluminum joists are also contemplated for use. The high strength-to-weight ratio of steel and aluminum makes these materials particularly suitable for forming joists. Those skilled in the art will understand that joists do not need to have an MS Tophat profile, but can be any shape that allows them to be used as beams, including, for example, open-web steel joists and rectangular hollow steel sections. Similarly, there is no need to provide a ribbed profile in the thermoplastic skin to accommodate the steel joists. As described below, a ribbed profile that matches the profile of joists 130 and 230 provides an advantage in forming the sandwich panels or building modules of the present invention.

[0082] Once formed, the sandwich panel of this invention is encased in a thermoplastic skin, which provides the panel with weatherproof and durable properties. The combination of metal / steel support beams and foam material gives the thermoplastic skin panel greater rigidity, allowing the panel to span greater lengths between supports.

[0083] Building Modules

[0084] refer to Figure 2A The diagram illustrates a building module 10 as a mezzanine panel. The building module 10 includes a first region 11, a second region 12, and a third region 13. The first region 11 provides the roof structure portion of the building, the second region 12 provides the wall structure portion of the building, and the third region 13 provides the floor structure portion of the building.

[0085] For functional reasons, it is generally desirable for the floor area of ​​a building module to be flat. While the preferred embodiment advantageously has a roof area sloped at 3 degrees to allow rainwater runoff, it also has curved wall areas, as discussed further herein; other arrangements are also contemplated.

[0086] In this example, regions 11 and 13 have a structure with a mezzanine 200, including steel support beams and containing, for example, Figure 1 The foam material shown has an insulating core, a ribbed outer skin, a flat inner skin, and a lip 226 (Fig. 2), which fits onto the top 227 of the adjacent building module. Region 12 includes a thermoplastic skin with a cross-section corresponding to region 11 / 13, but filled only with foam material. The curved wall region 12 is non-load-bearing and therefore has no steel support beams.

[0087] Figure 2BAnother building module 20, generally corresponding to building module 10, is shown, comprising a first region 11, a second region 12, and a third region 13. Building module 20 also includes a slot 21 in region 13 and an opening 22 at the junction of regions 12 and 13. The use of the slot 21 and the opening 22 is described below with reference to a preferred method of constructing the building. Steel beams within each module 20 extend parallel to the slots and openings in each panel and are located on either side of the slots and openings in each panel. The crossbeams within each module will not cross the entire panel when interrupted by the slot 21.

[0088] In the illustrated embodiment, the width W of building modules 10 and 20 is 2000 mm, but it should be understood that other widths may be used.

[0089] Multiple building modules can be assembled together to provide the floor, wall, and roof structure, cladding, and insulation for a building of a required length L, where L is a multiple of the width W of the building module. A method for constructing a building using building module 20 will be described in detail below.

[0090] Methods for forming sandwich panels and building modules

[0091] The thermoplastic surface layer or building module 10 or 20 of the sandwich panels 100, 200 can be formed by rotational molding. This involves forming the skin of the sandwich panel from thermoplastic in a rotary oven. This will produce a fully enclosed hollow skin 120, 220.

[0092] Rotational molding ovens can be used to manufacture larger items, such as storage containers, water tanks, and playground equipment. The building module of this invention can be integrally molded in a large rotary oven. In a preferred embodiment, the building module 10 is approximately 7 meters long and approximately 3 meters high. Suitable ovens are available, for example, from Galloway International, a New Zealand company.

[0093] Once the outer layer has solidified / cured, it can be demolded. To insert the steel support beam into the mezzanine, one end of the plate needs to be cut off, and then the support beam can be slid into place. In the case where the mezzanine is building module 10, the ends of the roof area 11 and floor area 13 of the building module are cut off, and then the support beam can slide into place in areas 11 and 13. As described above, in the preferred embodiment, the steel support beams are fixed to each other using crossbeams, such as 100mm steel cap support beam rivets, which are fixed above the support beam at regular intervals at a center of 600mm, ensuring that the steel support beam is firmly located in the groove.

[0094] Once the steel support beam is inserted, the panel is filled with foam material, in a preferred embodiment, polyurethane foam, ensuring that the entire cavity of the sandwich panel is filled. For the U-shaped building module of the present invention, this can be achieved by orienting areas 11 and 13 of the panel upwards and then pouring or injecting the foam material. Once the foam material hardens, any excess material is cut flush with the cut panel ends. The ends of the panels can then be sealed by heat welding, using previously removed panel ends, or by using custom-made caps, followed by heat sealing using a custom-made heating plate to melt the cut ends and reseal.

[0095] In embodiments using mycelial composite materials, instead of pouring or injecting foam material into the panel, the substrate can be inoculated with mycelial spores and then inserted into the thermoplastic skin. After a period of growth, the mycelium can be dried or heated to form the mycelial composite material. Another method for forming the thermoplastic skin is extrusion. The entire skin 120, 220 can be extruded through a die to provide the desired skin profile, or multiple separate portions of the skin, such as ribbed sides 222 and flat sides 224, can be formed by extrusion and then welded together. Support beams can then be inserted and the ends sealed, as in a rotational molding process. To form building module 10 or 20, the extruded part must be bent or wrapped around the die while in a plastic state.

[0096] Those skilled in the art will understand that the sandwich panels 100, 200 can be used to form roofs, floors, or walls. While the ribbed profiles form the exterior of building modules 10 or 20, they have... Figure 1 The planar sandwich panel with the cross-section shown can be used with ribbed profiles facing the interior or exterior of the building.

[0097] Alternative methods for forming sandwich panels and building modules

[0098] Rotational molding can be used to form sandwich panels and building modules in which steel support beams are already placed within a thermoplastic skin. This can be achieved by placing the steel support beams within a mold for the sandwich panel skin and holding them in place by multiple suitable supports, such as spacers or other suitable spacer elements.

[0099] Then, by adding thermoplastic material, rotating the mold in a rotary oven, and allowing the thermoplastic to solidify / cure, the skin of the sandwich panel can be formed in the mold. Once the skin has solidified / cured, the thermoplastic skin with steel support beams can be demolded. The sandwich panel can then be filled with insulation material by forming holes in it.

[0100] In some embodiments, the insulating foam is formed from powder, and the powder is inserted into the thermoplastic skin while it is still warm, i.e., immediately after it has formed in the rotary oven. One or more holes are formed in the thermoplastic skin, for example, by drilling, and then the powder is inserted. After the powder is inserted, the drilled holes are plugged. The mold containing the thermoplastic skin is then further rotated in the oven at a temperature below the melting temperature of the thermoplastic skin. The powder expands into foam within the mold and adheres to the thermoplastic skin. After the sandwich panel cools, it is removed from the mold as a seamless, monolithic piece. In a particularly preferred embodiment, the thermoplastic skin is formed of HDPE and the powder is polyethylene powder.

[0101] The advantage of this method is that it eliminates the need to remove the end of the mold to insert the steel support beam and then reseal the end back onto the mold. Furthermore, in embodiments using an HDPE skin and polyethylene powder, the adhesion between the individual polymers is enhanced. The resulting sandwich panel / building module is seamless and has a smooth surface, and the manufacturing process is simple. Due to the rotational molding process, this method results in some thermoplastic material adhering to the steel support beam within the mold, which is expected to lead to a higher demand for thermoplastic material in each sandwich panel / building module.

[0102] Method of constructing a building using building modules

[0103] Those skilled in the art will understand that the building modules of the present invention can be connected to each other and fixed to the ground in a variety of ways to construct buildings. A preferred method is described below.

[0104] In a preferred embodiment, a helical pile system is used. Helical piles made of steel are available, for example, from Katana Foundations (NZ). The advantages of helical piles are their ease of positioning and rapid installation. They also do not require concrete pouring and are suitable for deep to soft soil conditions throughout New Zealand. Helical piles can be removed, allowing the proposed building to be relocated or recycled at the end of its life. In this example method, the helical piles are installed in the ground in a grid arrangement, and each helical pile supports a steel column P. Helical pile extensions can be attached to the top of the helical pile above ground. As used herein, the term "helical pile" refers to a helical pile with or without helical pile extensions.

[0105] The method in this example uses building modules 20, which slide against each other as further described below. Slots 21 and holes 22 are useful in the construction method, but once the building structure system has been erected, all slots and all unused holes 22 are filled with molded inserts of appropriate shapes to fit the slots 21 and holes 22.

[0106] Figure 3and 4 The grid arrangement of the steel column P at positions P1, P2, etc., is shown. Slot 21 and hole 22 ( Figure 3 Not shown in the image; Figure 4 (As shown in the diagram) accommodates steel columns P. Columns P are arranged in two parallel rows R and S ( Figure 4 The spacing between the R-row columns and the S-row columns is 2W, and the distance between the R-row columns and the S-row columns is X( Figure 3 In the illustrated embodiment, X is 4300 mm.

[0107] Although Figure 3 and 4 A floor plan of a building formed by seven building modules 20 is shown, but it should be understood that any number of building modules 20 can be used to form a building in this manner.

[0108] like Figure 4 As shown, each building module 20 includes a slot 21 extending from the end of region 13 to a desired location in row R, and an opening 22 at a desired location in row S. The distance X2 between the opening 22 and the periphery of the building module 20 should be sufficient to position the opening 22 in the bottom region 13 rather than in the curved wall region 12. In the example shown, the distance X2 is approximately 1650 mm and typically corresponds to the radius of the curved wall region 12.

[0109] Figure 5 A schematic front view of a structural system for buildings according to the present invention is shown. In this figure, the nominal position G represents the ground line, and the broken line Rb indicates that the proportion of the helical pile R above the ground is uncertain. Adjacent helical piles can be coupled above the ground as needed via cross bracing.

[0110] Typically, a square drive head can be welded to the top of the shaft of each helical pile. This facilitates the installation of the helical pile and allows the shaft to be connected to the upper post or helical pile extension via a collar, such as... Figure 5 As shown in Rc. The collar advantageously includes a plate or a square nut welded to its inner wall to secure the collar to a square drive head. As is known in the art, the collar may also include retaining holes for piercing the pile shaft and / or column, such as M12 bolts.

[0111] To construct this structure, two rows of R and S helical piles are installed in any order, with their spacing related to the width W of the building modules. In the illustrated embodiment, the spacing 2W is twice the width W of the building modules, and only every other building module is fixed to the helical piles. Figure 5 The spacing can also be, for example, equal to the width W of the building module, in which case each building module will be fixed to a helical pile or another arrangement that those skilled in the art will understand.

[0112] The distance between the two rows of R and S corresponds to the distance between the hole 22 and the end of the slot 21 on the building module 20.

[0113] Once each row of R and S is installed, column P can be secured to the helical piles in row R, and load-bearing beam 23 can be secured to rows R and S respectively, with its height set to support the floor area 11 of the building module. These steps can be performed in any order, provided that column P has not yet been secured to row S. The load-bearing beam must be secured to the helical piles in row S, but load-bearing beam 23 can be secured to the helical piles in row R (i.e., below collar Rc), or to column P in row R (i.e., above collar Rc, such as...). Figure 5 (As shown).

[0114] The load-bearing beams 23 can be fixed to the R-row and S-row respectively using methods known in the art. The load-bearing beams can be any suitable material and profile; the preferred material is hot-dip galvanized steel, preferably a parallel flange channel (PFC) profile, which is corrosion-resistant, and those in the R-row can, for example, use clamps and bolts 25 (such as...). Figure 5 (As shown) Fixed to column P).

[0115] In this example, each post P is 89SHS and is connected to a helical pile via a collar formed of 100SHS, the helical pile having a circular hollow section (CHS) and a square drive head corresponding to the width of post P. However, post P can be any desired shape, including, for example, a CHS post.

[0116] Once the methods known in the art are used, the column P is installed along row R, and the beam 26 is fixed along row R to the top of the column P to support the roof area 11. Figure 5 In this example, the fixing device is via clamps and bolts 27. The corresponding frame will be constructed along row S, but has not yet been constructed. Therefore, in this example, the entire frame (top beam 26 and load-bearing beam 23) is installed along row R, and load-bearing beam 23 is installed to row S before the modules are fixed to the frame.

[0117] Next, the slot 21 of the first building module 20 slides onto the first post P1 of row R, aligning the hole 22 with the helical pile P2 of row S. Figure 3 Then the slot 21 of the first building module can be plugged with an HDPE molded insert. When or after all building modules 20 are in place, the column P2 in the S row can then be installed into the helical pile P2 through the hole 22.

[0118] Molded inserts can be supplied in suitable shapes to fit the shapes of slots 21 and holes 22, and can also be formed using a rotational molding process. In this example, the molded inserts are also filled with PUR foam to increase rigidity. Once the modules are mounted on the frame, they can be heat-welded into place.

[0119] The lip of the second module is then aligned with the complementary top of the first module, and the second building module slides onto the first building module. In the illustrated embodiment, the second building module 20 is not mounted to the helical pile; it is secured to the first module by friction fit. This means that the slots 21 and holes 22 of the second building module 20 will not function and can be plugged with HDPE molded inserts.

[0120] Alternatively, the slots 21 and holes 22 can be omitted from every other building module. The advantage of providing slots 21 and holes 22 for each building module is that only one mold is needed to form the building modules, and it provides flexibility during installation.

[0121] It should be understood that, in alternative embodiments, each building module will have a pair of complementary helical piles, and each slot 21 and hole 22 will receive a column P.

[0122] In this example, the length of slot 21 is approximately 1m. Therefore, once installed, the floor area of ​​each module will extend beyond the grid line R1m. Figure 4 Alternatively, instead of raising the area above the floor in this way, additional steel beams within each slot 21 can be used to support the steel end beams (not shown) below the ends of area 13. Advantageously, the railings can be fixed to these additional steel end beams.

[0123] As described above, once each building module is installed on the frame along row R, columns P2, P4, etc., can be installed onto the helical piles P2, P4, etc. through holes 22. When all columns in row S are in place, a second beam (not shown) can then be fixed to the top of the second row columns P2, P4, etc., using methods known in the art, to provide a second frame along row S and support the roof area 11.

[0124] The dimensions of column P and beam can be calculated using methods known in the art, taking into account the required span and material of the beam, as well as the load borne by the beam / column. The building module of this invention is robust and lightweight. For the unloaded building module 20, a column width of 89 mm is expected to be sufficient. This does not take snow load into account; it is also envisioned that this invention will allow for buildings with green roofs, which increases the load on the structural frame. Known methods can be used to calculate how much additional dimensions are needed for column P and roof beam in this case. The width of hole 22 and slot 21 is controlled by the width of column P; for example, hole 22 has a diameter of 120 mm to accommodate a steel column with a width of 89 mm.

[0125] The roof area 11 and the floor area 13 can be secured to the corresponding beams by screwing them into the steel joists within the panels.

[0126] Although Figure 3 and 4The accompanying text describes preferred methods for securing building modules to the ground; however, it should be understood that the general method of creating holes in the floor area of ​​the building module can be applied to accommodate any foundation system.

[0127] Completed buildings

[0128] After the building shell is formed by the above method, aluminum joinery products, such as double-glazed sliding doors and windows, or other partition wall systems can be installed on the open side of the building shell. Figure 6 A perspective view of this building is shown. Joinery can be secured to areas 11 and 13 using bolting and / or thermal welding techniques. Partition walls can be constructed into the interior of the building using similar bolting and / or thermal welding techniques. Figure 7 An exemplary single-bedroom floor plan is shown, illustrating the partition wall; those skilled in the art will understand that many variations are possible.

[0129] The surfaces of the thermoplastic and HDPE in the illustrated embodiments are durable and require no painting or other surface treatments, and as mentioned above, green roofing systems are acceptable if desired. The inner surface of the thermoplastic provides the floor surface and the outer deck. This can provide a finished floor surface, or alternatively, a finished floor surface can be provided on top of the thermoplastic using another flooring system.

[0130] It should be understood that if any prior art patent disclosure is cited in this document, such citation is not an admission that such patent disclosure is part of common general knowledge in the field in New Zealand or any other country.

[0131] In the following claims and the foregoing description of the invention, unless the context requires otherwise due to the language of expression or necessary implication, the word "comprising" or variations such as "including" are used in an inclusive sense, that is, specifying the presence of the said feature but not excluding the presence or addition of other features in various embodiments of the invention.

Claims

1. A building module, the building module being a sandwich panel, comprising: An inner core comprising a foam material; as well as An outer skin comprising a thermoplastic material that completely surrounds the inner core; A first area, a second area, and a third area, wherein the first area provides the roof structure portion of the building, the second area provides the wall structure portion of the building, and the third area provides the floor structure portion of the building; as well as Metal support beams in the outer skin of the first and third regions.

2. The building module according to claim 1, characterized in that, The outer skin includes at least one end plate.

3. The building module according to claim 1, characterized in that, The metal support beam is a steel support beam with a cap-shaped profile.

4. The building module according to claim 1, characterized in that, The surface of the sandwich panel has a ribbed profile to accommodate the metal support beam.

5. The building module according to claim 1, characterized in that, The foam material is selected from: polyurethane foam, polyethylene foam, foam formed from recycled polyethylene terephthalate (PET), or any combination thereof.

6. The building module according to claim 5, characterized in that, The polyurethane foam is formed using carbon capture technology.

7. The building module according to claim 1, characterized in that, The thermoplastic material is HDPE.

8. The building module according to claim 1, characterized in that, The first and third regions are substantially planar, while the second region is substantially curved into a semi-circle, making the building module roughly U-shaped.

9. A building module, the building module being a sandwich panel, comprising: The building comprises a first region, a second region, and a third region, wherein the first region provides a roof structure portion of the building, the second region provides a wall structure portion of the building, and the third region provides a floor structure portion of the building; wherein the first and third regions are sandwich panels containing metal joists within a single outer skin; wherein the building module has slots and holes, the slots extending from the end of the third region toward the second region to accommodate metal supports, and the holes located at the junction of the second and third regions to accommodate metal supports.

10. The building module according to any one of claims 1 to 9, characterized in that, The contours of the first side edge of the sandwich panel are complementary to the contours of the second side edge, allowing the building module to be joined to adjacent building modules without fasteners.

11. The building module according to claim 10, characterized in that, The first side edge includes a lip and the second side edge includes a complementary top.

12. A method of constructing a building module according to any one of claims 1 to 11, wherein the building module is a sandwich panel, comprising: a. Forming the outer skin of a sandwich panel made of thermoplastic in a rotary oven and allowing the thermoplastic to solidify; b. After the outer skin has solidified, the outer skin is demolded and at least one end of the sandwich panel is removed; c. Insert the metal support beam into the sandwich panel; d. Fill the sandwich panel with foam material and harden the foam material; or fill the sandwich panel with a substrate inoculated with mycelium, and dry or heat the mycelium after the growth period to form a mycelium composite material; e. Once the foam material has hardened or formed the mycelial composite material, the excess foam material or mycelial composite material is cut flush with the ends of one or more sandwich panels.

13. A method of constructing a building module according to any one of claims 1 to 11, wherein the building module is a sandwich panel, comprising: a. Forming the outer skin of a sandwich panel made of thermoplastic in a mold in a rotary oven, and allowing the thermoplastic to solidify; b. After the outer skin has solidified, the outer skin is demolded and at least one end of the sandwich panel is removed; c. Insert the metal support beam into the sandwich panel, and insert foam into the sandwich panel to form powder; d. Place the sandwich panel and the removed one or more ends back into the mold; close the mold and rotate it in the rotary oven at a lower heat to re-thermally bond the removed one or more ends to the sandwich panel, and to cause the foam forming powder to expand into foam within the thermoplastic outer skin.

14. The method according to any one of claims 12 to 13, characterized in that, In step b, remove both ends of the sandwich panel.

15. A method of constructing a building module according to any one of claims 1 to 11, wherein the building module is a sandwich panel, comprising: a. Extruding the outer skin of the sandwich panel made of thermoplastic in an extrusion die; b. Allow thermoplastics to solidify; c. Insert the metal support beam into the sandwich panel; d. Fill the sandwich panel with foam material and harden the foam material; or fill the sandwich panel with a substrate inoculated with mycelium, and dry or heat the mycelium after the growth period to form a mycelium composite material; e. Once the foam material has hardened or formed the mycelium composite material, the excess foam material or mycelium composite material is cut flush with the ends of the multiple sandwich panels.

16. The method according to claim 15, characterized in that, The method further includes, after step a, heating the extruder and bending the extruder around a template.

17. The method according to any one of claims 12, 15, and 16, characterized in that, The method also includes covering the sandwich panel with a thermoplastic end plate using a thermal welding process.

18. The method according to claim 12, characterized in that, The method further includes covering the sandwich panel with the end plate removed in step b using a thermal welding process.

19. A method of constructing a building module according to any one of claims 1 to 11, wherein the building module is a sandwich panel, comprising: a. Place the metal support beam inside the mold on the outer skin of the sandwich panel, the metal support beam being fixed in place by a plurality of suitable spacer elements; b. The outer skin of the sandwich panel is formed in the mold by adding a thermoplastic material, and then the mold is rotated in a rotary oven; c. (i) Allowing the thermoplastic to solidify, then demolding the outer skin containing the metal support beams, and then forming a hole in the sandwich panel and filling the sandwich panel with an insulating material; or (ii) The thermoplastic material is solidified, and while the thermoplastic outer skin is still warm, a hole is formed in the sandwich panel and the sandwich panel is filled with a heat-insulating material. Then, the mold containing the thermoplastic outer skin is further rotated in the rotary oven at a temperature lower than the melting temperature of the thermoplastic outer skin, and then the sandwich panel is demolded.

20. The method according to claim 19, characterized in that, The insulation material in step c(ii) is a foam-forming powder containing polyethylene.

21. The method according to any one of claims 12, 13, 15, and 19, characterized in that, The metal support beams are interconnected by crossbeams fixed between them.

22. The method according to any one of claims 12, 13, 15, and 19, characterized in that, The sandwich panel includes a first region, a second region, and a third region, the first region and the third region being substantially planar, and the second region being substantially curved into a semi-circle, such that the sandwich panel is approximately U-shaped.

23. The method according to any one of claims 12, 15, and 16, characterized in that, The sandwich panel includes a first region, a second region, and a third region, wherein the first and third regions are substantially planar, and the second region is substantially curved into a semi-circle, such that the sandwich panel is generally U-shaped, and the sandwich panel is filled with the foam material or matrix. The U-shaped sandwich panel is erected vertically, and the foam material is poured into it in a controlled manner from the top of the U-shape, thereby filling the entire cavity of the sandwich panel without any gaps.

24. A method for constructing a building from a plurality of building modules as described in any one of claims 1 to 11, characterized in that, The method includes: a. Secure the first building module to the appropriate location on the ground; b. Align the lip of the second building module with the complementary top of the first building module, and slide the second building module onto the first building module; c. Align the lip of the third building module with the complementary top of the second building module, and slide the third building module onto the second building module; d. Repeat steps b and c until all building modules are installed; e. Secure the last building module in the appropriate position relative to the ground.

25. The method according to claim 24, characterized in that, The second building module is fixed in a suitable position relative to the ground.

26. The method according to claim 24, characterized in that, The building module is the building module as described in claim 9, and the method of fixing the building module to the ground includes inserting helical piles into appropriate positions in the ground corresponding to the end of a slot in each building module fixed to the ground, thereby forming a first row of helical piles; and inserting helical piles into appropriate positions in the ground corresponding to holes in each building module fixed to the ground, thereby forming a second row of helical piles.

27. The method according to claim 26, characterized in that, It also includes fixing a load-bearing beam to each of the helical piles in the first row of helical piles, and fixing another load-bearing beam to each of the helical piles in the second row of helical piles.

28. The method according to claim 26, characterized in that, It also includes, prior to step a, installing the column onto each of the first row of helical piles and securing the load-bearing beam to the top of the column in the first row of helical piles.

29. The method according to claim 28, characterized in that, It also includes, after step e, installing the column onto each of the helical piles in the second row of helical piles, and fixing the load-bearing beam to the top of the column in the second row of helical piles.

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