Building module

Abstract

A module for a modular building, the module comprising a base, a ceiling (4) and two sidewalls, the base, ceiling (4) and sidewalls delimiting an inner space (12), at least one of: the base, the ceiling (4) and the sidewalls having: a layer (20) of a first concrete material facing the inner space (12); a layer (22) of an insulating material arranged over the layer (20) of first concrete material; and a layer (36) of a second concrete material arranged over the layer (22) of insulating material.

Description

Technical Field

[0001] This disclosure pertains to the field of civil engineering and more particularly to the construction of buildings and the like, from modular elements.Background Art

[0002] Constructing a building by assembling pre-cast walls or pre-cast modules has been known for years. For example, the patent application DE 2 926 969 A1 discloses precast modules for constructing a building. Insulation bodies are interposed between two adjacent walls, in grooves of the walls. The insulation bodies are segmented and are not efficient to isolate properly.

[0003] Document US 4,443,992 A shows a method for constructing a building unit where walls that have been individually prepared are assembled on a steel structure.

[0004] Document US 2007 / 0095006 A shows the construction of a portable unit. A metallic structure is built and concrete is sprayed therein.

[0005] There is therefore a need for improved modules which have better insulation properties.Summary

[0006] This disclosure improves the situation with a module according to claim 1.

[0007] By providing an entire layer of insulating material, the insulation is improved.

[0008] According to the invention, the layer of insulating material comprises a plurality of grooves and the layer of second concrete material embeds steel rods received in the grooves of the insulating material.

[0009] Thus, the intertwining of steel rods in grooves of the insulating material further improves the insulation while not degrading the strength of the module.

[0010] In another aspect, the grooves are arranged in at least one zone of the layer of insulating material, and the layer of insulating material has a second thickness comprised between 10 and 20 cm in the at least one zone. Hence, the grooves in thicker zones of the insulating material, thereby providing a complete layer of insulating material below the grooves. In other words, when the grooves are arranged in a single-thickness layer, the performance of the insulation is reduced.

[0011] In another aspect, the grooves are arranged in at least two zones separated from one another by a central groove.

[0012] According to the invention, at a junction between the ceiling and the sidewalls or between the base and the sidewalls, the respective layers of insulating material contact one another.

[0013] It is therefore possible to isolate completely the inner space of the module from the environment.

[0014] In another aspect, the layer of insulating material has a first thickness comprised between 3 and 7 cm, at least at an edge of the layer of insulating material.

[0015] According to the invention, the insulation material is a thermal insulator.

[0016] In another aspect, the first concrete material is a force metal concrete. In some examples, the first concrete material comprises glass fibers, for instance arranged as a fibers mesh. In some examples, the first material comprises gravel recycled from building materials, and the concrete is then reinforced with regular steel rebar or fibers.

[0017] In another aspect, at least one of the base, the ceiling, and the sidewalls, embeds wiring or pipes. It is thus not necessary to grill holes in the precast module once on-site: the insulation performance is therefore not reduced by adaptations that could be needed when assembling the modules.

[0018] In another aspect, the layer of the first concrete material has a thickness that is comprised between 3 and 5 cm. The thickness is preferably 4 cm.

[0019] In another aspect, the base and the ceiling have a length that is comprised between 3 meters and 10 meters. The length is preferably 6 meters.

[0020] In another aspect, the base, the ceiling and the sidewalls have a depth that is comprised between 2 and 4 meters. The depth is preferably 2.40 meters.

[0021] In another aspect, the sidewalls have a height that is comprised between 2.5 meters and 8 meters. The height is preferably 3 meters.

[0022] In another aspect, the module further comprises a male connector protruding from an outer surface of the base, the ceiling or sidewalls, configured for the connection with a female connector of an adjacent module.Brief Description of Drawings

[0023] Other features, details and advantages will be shown in the following detailed description and on the figures, on which: Figure 1 shows two modules. Figure 2 is a partial see-through view of the ceiling. Figures 3 and 4 are cross-sectional views of a junction between the ceiling and a sidewall. Figure 5 shows an example of connector between modules. Description of Embodiments

[0024] Figure 1 shows an example of two modules 1 which may be used to build a modular building 10. The modules 1 are precast and are then brought on a construction site where they are assembled to form a modular building.

[0025] The modules 1 may have a general shape that is stackable in one or more directions X, Y, Z. For example, the modules 1 may be of a generally parallelepiped shape.

[0026] In this example, each module 1 has a base 2, a ceiling 4 opposite the base 2, and two sidewalls 6, 8. The base 2, the ceiling 4 and the sidewalls 6, 8 define an inner space 12 which will constitute the inside of the building. In the modules 1 that are shown, the inner space 12 is open at both ends. The modular building 10 may also comprise end modules, having a third sidewall closing the inner space at one end.

[0027] On figure 1, one can see an inner surface 2.1 of the base 2, an inner surface 6.1 of the sidewall 6, as well as an outer surface 4.2 of the ceiling 4 and an outer surface 8.2 of the sidewall 8. The outer surfaces 4.2, 8.2 may be the outer surfaces of the building, i.e., an additional insulation or covering is optional. Contrary to the inner surfaces of the base, ceiling and sidewalls, their outer surfaces do not face the inner space 12.

[0028] The sidewalls 6, 8, and / or the base 2 or ceiling 4, may comprise wirings or pipes, illustrated schematically with dashed lines 14. The sidewalls 6, 8 may contain openings receiving windows or doors. The base 2 and / or the ceiling 4 may comprise openings for stairs or for a lift.

[0029] Two or more modules 1 may be stacked onto one another to form several floors of a building. To that end, the modules 1 may comprise a (releasable) mechanical coupling. In the illustration, the lower module 1 has a recess 16 on the outer surface of its ceiling and the upper module 1 has a protrusion 18 on the outer surface of its base. The recess 16 and the protrusion 18 may engage one another as the upper module 1 is lowered down (e.g., by a crane) onto the lower module 1. Other types of complementary shapes may be used. For example, the recess 16 may be arranged on the upper module 1 and the protrusion 18 may be arranged on the lower module 1. An example of a mechanical coupling is described in figure 5.

[0030] The module 1 may have a height H that is comprised between 2.5 meters and 8 meters. A preferred height is of about 3 meters.

[0031] The module 1 may have a depth D comprised between 2 and 4 meters. A preferred depth is of about 2.40 meters.

[0032] The module 1 may have a length L that is comprised between 3 meters and 10 meters. A preferred length is of about 6 meters.

[0033] Figure 2 shows an example of the constitution of the ceiling 4. Alternatively or in complement, the base 4 or the sidewalls 6, 8 may be formed as shown on figure 2.

[0034] On an inner side (facing the inner space 12), a layer 20 of a first concrete material is formed. This layer 20 may have a thickness h20 that is comprised between 3 and 5 cm. In some preferred examples, the thickness h20 is of about 4 cm. The first concrete material may be a force metal concrete.

[0035] Over the first layer 20 is arranged a layer of insulating material 22. The insulating material may cover substantially the entirety of the first layer 20, i.e., at least 90% of the first layer. In some cases, the insulating material covers the entirety of the first layer. As can be seen on figures 3 or 4, the insulating layer may protrude beyond the first layer. The insulating material is a thermal insulator. The layer 22 of insulating material may have at least one edge 24 having a small thickness h24 which may be comprised between 3 and 7 cm, for example 5 cm. The layer 22 may also have one or more zones 28, 30 (here two) having a higher thickness h28 comprised between 10 and 20 cm, for example 13 cm. The zones 28, 30 may be separated from one another by a central groove 26. Each of the zones 28, 30 may have a square shape. Each of the zones 28, 30 may have a width that is at least 60% of the depth D of the module 1. The zones 28, 30 may accommodate an array of grooves 32, 34. The array of grooves 32, 34 may comprise grooves 32 extend parallel to a length direction X of the module 1 and grooves 34 which extend parallel to the depth direction Y of the module 1.

[0036] The grooves 32, 34 receive steel rods 38 of a layer 36 of a second concrete material. The steel rods 38 are placed in the grooves 32, 34 prior to concrete material being poured on the insulating layer 22. The thickness of the layer 36 of second concrete material may be comprised between 10 and 30 cm.

[0037] Figures 3 and 4 show two examples of the junction between the ceiling 4 and the sidewall 6. These arrangements may alternatively or complementarily be provided at other junctions between the ceiling and other sidewalls or between the base and other sidewalls.

[0038] In both cases, the insulating layers 22A, 22B are in contact with one another at an interface noted C. Thus, the inner surfaces 4.1, 6.1 are isolated from the outer surfaces 4.2, 6.2. There is therefore no thermal bridge between the exterior and the interior of the building.

[0039] To achieve this contact between the insulating layers 22A, 22B, several arrangements are possible. Figures 3 and 4 show two of them.

[0040] On figure 3, the sidewall 6 goes all the way up. The interface between the layers 36A, 36B of second concrete material is vertical. The same goes for the interface between the layers 20A, 20B of first concrete material. The layers 22A, 22B of insulating material protrude beyond the layers 20A, 20B of first concrete material.

[0041] On figure 4, the interface between the layers 36A, 36B of second concrete material is horizontal while the interface between the layers 20A, 20B of first concrete material is vertical. In this example, the layers 20A, 22A and 36A are flush. The layer 36B protrudes beyond the layer 22B, which in turb protrudes beyond the layer 20B. The arrangement of figure 4 may be preferred as it may be easier to manufacture and to assemble.

[0042] Figure 5 shows an example of releasable mechanical coupling or connector, for connecting a top module on a lower module, similar to numbers 16 and 18 of figure 1. In this case, a nut assembly 50 is arranged in a recess 51 of a lower module 1. The nut assembly 50 comprises a nut 52 which may be solidly fixed (or welded) to steel rods 38 of the second concrete material of the ceiling of the lower module.

[0043] A screw assembly 60 may be engaged in the nut assembly 50. The screw assembly 60 comprises a threaded rod 62, a hexagonal head 64 and a conical hat 66. The screw assembly 60 may engage the nut assembly 50 prior to the top module being lowered down onto the lower module. The arrangement is such that the conical hat 66 protrudes above the outer layer 4.2 of the ceiling of the lower module. The top module may have a conical recess of a size substantially mirroring the conical hat 66, such that as the top module is lowered down onto the lower module, the conical recess engages the conical hat 66.

[0044] The lower module may comprise four arrangements as described on figure 5, one per corner.Reference Signs List

[0045] 1: Module 2: base 2.1: inner surface of the base 2 4: ceiling 4.1: inner surface of the ceiling 4 4.2: outer surface of the ceiling 4 6, 8: sidewalls 6.1: inner surface of the sidewall 6 6.2: outer surface of the sidewall 6 8.2: outer surface of the sidewall 8 10: modular building 12: inner space 14: wires, pipes 16, 18: mechanical coupling 20, 20A, 20B: layer of a first concrete material 22, 22A, 22B: layer of insulating material 24: edge of the layer of insulating material 26: central groove 28, 30: zones of higher thickness 32, 34: grooves 36: layer of second concrete material 38: steel rods 50: nut assembly 51: recess 52: nut 60: screw assembly 62: threaded rod 64: hexagonal head 66: conical hat C: junction of two layers 22A, 22B of insulating material

Claims

1. A module (1) for a modular building (10), the module (1) comprising a base (2), a ceiling (4) and two sidewalls (6, 8), the base (2), ceiling (4) and sidewalls (6, 8) delimiting an inner space (12), the base (2), the ceiling (4) and the sidewalls (6, 8) having: an inner surface (2.1, 4.1, 6.1); an outer surface (2.2, 4.2, 6.2); a layer (20) of a first concrete material facing the inner space (12); a layer (22) of an insulating material arranged over the layer (20) of first concrete material; and a layer (36) of a second concrete material arranged over the layer (22) of insulating material, wherein the insulation material is a thermal insulator, wherein at a junction between the ceiling (4) and the sidewalls (6, 8) or between the base (2) and the sidewalls (6, 8), the respective layers (22A, 22B) of insulating material contact one another, such that the inner surfaces (2.1, 4.1, 6.1) are isolated from the outer surfaces (2.2, 4.2, 6.2) preventing a thermal bridge between the exterior and the interior of the building module, wherein the layer of insulating material comprises a plurality of grooves (32, 34) and the layer (36) of second concrete material embeds steel rods (38) received in the grooves (32, 34) of the insulating material.

2. The module (1) of claim 1, wherein the grooves (32, 34) are arranged in at least one zone (28, 30) of the layer (22) of insulating material, and the layer (22) of insulating material has a second thickness (h28) comprised between 10 and 20 cm in the at least one zone (28, 30).

3. The module (1) of claim 1 or 2, wherein the grooves (32, 34) are arranged in at least two zones (28, 30) separated from one another by a central groove (26).

4. The module (1) of any of the preceding claims, wherein the layer (22) of insulating material has a first thickness (h20) comprised between 3 and 7 cm, at least at an edge (24) of the layer (22) of insulating material.

5. The module (1) of any of the preceding claims, wherein the first concrete material is a force metal concrete optionally comprising glass fibers.

6. The module (1) of any of the preceding claims, wherein at least one of the base (2), the ceiling (4), and the sidewalls (6, 8), embeds wiring or pipes (14).

7. The module (1) of any of the preceding claims, wherein the layer (20) of the first concrete material has a thickness (h20) that is comprised between 3 and 5 cm.

8. The module (1) of any of the preceding claims, wherein the base (2) and the ceiling (4) have a length (L) that is comprised between 3 meters and 10 meters.

9. The module (1) of any of the preceding claims, wherein the base (2), the ceiling (4) and the sidewalls (6, 8) have a depth (D) that is comprised between 2 and 4 meters.

10. The module (1) of any of the preceding claims, wherein the sidewalls (6, 8) have a height (H) that is comprised between 2.5 meters and 8 meters.

11. The module (1) of any of the preceding claims, further comprising a male connector (18, 66) protruding from an outer surface of the base (2), the ceiling (4) or sidewalls (6, 8), configured for the connection with a female connector (16) of an adjacent module.

Images