Modular construction systems, panels therefore, and methods for reducing the thickness of construction panels to control cumulative errors at joints

Abstract

The present disclosure concerns a modular construction system, a panel for a modular construction system, and a method for reducing the thickness of a panel to control cumulative errors at joints. The

Description

TECHNICAL FIELD The invention relates to modular construction systems, panels therefore, and methods for reducing the thickness of construction panels to control tolerance and cumulative errors at joints. BACKGROUND Modular construction systems have gained significant attention in recent years due to their potential for reducing construction time, cost, and environmental impact. These systems typically involve the use of prefabricated building components, which can be assembled on-site to create a variety of building designs. One of the key challenges in the field of modular construction systems is the need for precise and accurate construction of building panels and their connections. This is particularly important given the reliance on sheet materials, such as plywood, oriented strand board (OSB), and other breathable alternatives, which can exhibit variations in thickness. Such variations can lead to issues with jointing, as well as inconsistencies in the finished external dimensions of an assembly. Traditional approaches to addressing these issues have involved the use of timeconsuming and labour-intensive processes, such as editing and recalibrating designs to suit exact material thicknesses. However, these methods are often impractical for large-scale projects and can result in increased costs and delays. In response to these challenges, various techniques have been developed to improve the accuracy and consistency of modular construction systems. For example, some systems employ the use of computer numerical control (CNC) technology to manufacture panel components with millimetre accuracy. Despite these advancements, there remains a need for further improvements in the field of modular construction systems. There is a need for methods and systems that can effectively manage variations in material thickness while maintaining the critical external dimensions of an assembly. Moreover, there is a need for modular construction systems that can be rapidly assembled on-site without the need for specialist contractors, thereby reducing construction time and cost. Furthermore, there is a growing demand for sustainable and environmentally friendly building solutions. As such, there is a need for modular construction systems that are designed and engineered to be part of a circular economy, with minimal waste and a reduced carbon footprint. This includes the use of sustainable materials, as well as the implementation of distributed networks of micro-factories for local production. Improvements are desired to overcome shortcomings of existing implementations. SUMMARY In general terms, the construction system of the present disclosure is directed to a modular construction system comprising building panels with a frame, an outer wall, and an inner wall. The outer wall of the panels has cut-outs in specific positions, which when two panels are put together, align to receive a joining plate, thereby allowing the panels to be joined together. Furthermore, the disclosure solves the problem of variations in sheet material thickness causing jointing and external dimension issues in prefabricated building systems, by incorporating T-pockets and a panel-to-panel connection method that ensures accurate, predictable joints and maintains critical external dimensions. The resulting construction can be assembled quickly and efficiently and provides an airtight building envelope in the form of a chassis that has many different design options. According to an aspect of the invention, there is provided a modular construction system. The system comprises a plurality of building panels. Each building panel comprises a frame forming panel side walls. The frame provides a frame front face and a frame rear face. An outer wall member is secured to the front face of the frame. An inner wall member is secured to the rear face of the frame. The outer wall member includes cut-outs in predetermined positions. When two panel side walls abut, a cutout of one panel is aligned with the cut-out of the other panel to receive a joining plate therebetween to join the two panels together. Optionally, each cut-out comprises pre-formed holes configured to concentrically align with pre-formed holes of the joining plate. The joining plate is secured to the cut-outs using bolts which screw into pre-inserted nuts in the pre-formed holes of the outer wall panels. Optionally, the inner wall member is recessed in from the frame rear face to form a services open-faced cavity, and the frame provides a peripheral lip around at least part of the inner wall panel. Optionally, the frame provides a peripheral lip around the entire periphery of the inner wall panel. Optionally, cut-outs are provided in the lip to receive and support delivery of services such as electrical wires or water pipes. Optionally, the cut-outs comprise u-shaped slots to create a friction interface for receiving electrical wires or water pipes. Optionally, the cut-outs comprise apertures for receiving and supporting electrical wires and water pipes. Optionally, each panel forms a substantially airtight hollow enclosure filled with insulation material. Optionally, the outer wall member and side walls comprise both male and female joint parts that are cooperable with one another in use. Additionally, the outer wall member and sidewalls are rebated in the region of the male and female joint parts such that the thickness of the outer wall member and sidewalls is controlled in the region of each of the male and female joint parts. Optionally, the thickness of the outer wall member and sidewalls in the region of the male and female joint parts is 16mm. Optionally, the sidewalls comprise at least one longitudinal slot and the inner wall member comprises at least one corresponding projection on each of its longitudinal edges. The projection of the inner wall member is received by the slot of the side wall. Optionally, the sidewalls comprise at least one projection extending from the longitudinal edge thereof and the outer wall member comprises at least one corresponding aperture in each of its longitudinal edges, wherein the at least one projection of the sidewall is received by the at least one aperture of the outer wall member. Optionally, the panel further comprises a top wall and a bottom wall, each of the top wall and bottom wall comprising at least one longitudinal slot, at least one lateral cutout, and at least one projection extending from the longitudinal edge thereof. The at least one longitudinal slot receives a corresponding projection of the inner wall member, the at least one lateral cut-out receives a corresponding lateral projection of a sidewall, and the at least one projection is received by a corresponding rebate of the outer wall member. Optionally, the panel further comprises an intermediate member extending between the outer wall member and inner wall member and being positioned centrally between the side walls. Optionally, the outer wall member comprises a longitudinal groove extending at least partially between opposing ends thereof for receiving an edge of the intermediate member. Optionally, each of the side walls comprises a longitudinal groove extending at least partially between opposing ends thereof for receiving an edge of the inner wall member. Optionally, adjacent panels may fix together using skewed fasteners, i.e., screws, nails or the like driven at an angle between adjacent panels. According to another aspect of the invention, there is provided a building panel. The building panel comprises a frame forming panel side walls, wherein the frame provides a frame front face and a frame rear face. An outer wall member is secured to the front face of the frame. An inner wall member is secured to the rear face of the frame. The outer wall member includes cut-outs in predetermined positions. When two panel side walls abut, a cut-out of one panel is aligned with the cut-out of the other panel to receive a joining plate to join the two panels together. According to another aspect of the invention, there is provided a method of reducing the thickness of a panel to control cumulative errors at joints. The method comprises the steps of cutting the length of the panel to a pre-determined size, machining joining features into the panel, and rebating the panel in the region of the joining features to control the thickness of the panel in the region of the joining features. Optionally, the panel has a thickness of between 17.5mm to 18.5mm. Optionally, the rebated areas of the panel have a thickness of 16mm. BRIEF DESCRIPTION OF THE DRAWINGS The above and other objects and advantages of the invention of the disclosures will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings in which: Figure 1 illustratively shows a view of a modular construction system according to the present disclosure. Figure 2 illustratively shows a first view of a building panel according to the present disclosure. Figure 3 illustratively shows a second view of a building panel according to the present disclosure. Figure 4 illustratively shows an exploded view of a building panel according to the present disclosure. Figure 5 illustratively shows a detail view of a portion of the building panel of Figure 4. Figure 6 illustratively shows a first stage of a modular building construction according to the present disclosure. Figure 7 illustratively shows a second stage of a modular building construction according to the present disclosure. Figure 8 illustratively shows a first view of a third stage of a modular building construction according to the present disclosure. Figure 9 illustratively shows a second view of the third stage of a modular building construction according to the present disclosure. DETAILED DESCRIPTION Figure 1 illustratively shows a modular construction system 10 according to the present disclosure. As illustrated, the modular construction system 10 may be utilised in the construction of a dwelling house. Alternatively, the modular construction system 10 may be utilised in the construction of outbuildings, commercial premises, workshops, stables, garaging, for example. The modular construction system 10 comprises a plurality of building panels 12. As shown in Figures 2 to 5, each building panel 12 has a frame forming panel side walls 14, a top 16, and a bottom 18. The frame provides a frame front face 20 and a frame rear face 22. An outer wall member 24 is secured to the frame front face 20, and an inner wall member 26 is secured to the frame rear face 22. The outer wall member 24 includes cut-outs 28 in predetermined positions such that when two panel side walls 12a, 12b abut, a cut-out 28a of one panel 12a is aligned with the cut-out 28b of the other panel 12b to receive a joining plate 30 to join the two panels 12, 12b together. Advantageously, the modular construction system 10 tackles the prevalent issue of sheet material thickness variation, which is a common challenge faced when using construction-grade materials such as plywood, OSB, and breathable alternatives. This innovative solution incorporates “T-pockets”, a unique design feature that ensures perfect joint fitting and maintains the critical external dimensions of the assembly, regardless of any variation in material thickness. The T-pockets are strategically designed recesses or channels that are machined into the jointed faces 32 of the building panels 12, allowing for precise alignment and connection between adjacent building panels 12. This is more particularly shown in Figure 5. To achieve this level of accuracy and predictability in the joints, the modular construction system 10 employs advanced CNC routing technology to machine all jointed faces 32 to an exact controlled thickness. This precise thickness control not only results in accurate and predictable joints but also allows for the use of various construction-grade materials with inherent thickness variations. By maintaining a consistent thickness in the region of the joint parts, the modular construction system 10 can ensure a precise and secure connection between building panels 12, enhancing the overall structural integrity stability, and appearance of the assembled modular building. The T-pocket design effectively transfers the variation in material thickness internally, preserving the critical external dimensions of the assembly. This ingenious approach eliminates the need for time-consuming design recalibration and constant monitoring of material thickness, which are typically required in conventional construction methods. As a result, the modular construction system 10 becomes more efficient, cost-effective, and suitable for large-scale projects, such as commercial buildings, residential complexes, and industrial facilities. Furthermore, the T-pocket design allows for easy and efficient panel-to-panel connections without the need for specialized tools or equipment. This streamlined assembly process not only reduces labour costs but also minimizes the potential for human error, ensuring a high-quality and consistent final product. Additionally, the T-pocket design can accommodate various panel shapes and sizes, providing architects and designers with the flexibility to create unique and innovative building designs that cater to specific project requirements and aesthetic preferences, all while adhering to modular building design principles. An example is illustrated in Figures 6 to 9. In terms of sustainability and eco-friendliness, the T-pocket design contributes to the overall energy efficiency of the modular construction system by minimizing thermal bridging and air leakage at the panel joints. This improved thermal performance reduces the building's energy consumption and associated carbon emissions, aligning with the growing demand for environmentally responsible construction solutions. In some embodiments the cut-outs 28 comprise pre-formed holes 34 configured to concentrically align with pre-formed holes of the joining plate 30 and the joining plate 30 is secured to the cut-outs 28 using bolts which screw into pre-inserted nuts in the pre-formed holes 34 of the outer wall panels 24. Advantageously, the prefabricated building system utilizes factory-made structural and insulated panels 12 that connect to form a structural, airtight, and insulated building envelope, known as a "batch chassis." the panel components are manufactured with millimetre accuracy using CNC technology from sheet materials such as plywood, OSB, and breathable alternatives. The panel construction comprises a closed receptacle filled with insulation and an open receptacle creating a service void. Panel-to-panel connections are made externally with joining plates 30 and internally with bolts / insert nuts through pre-cut holes in the service void. Skewed fasteners, i.e., nails or screws, may also be used both internally and externally. This innovative panel-to-panel connection method enables rapid assembly of the building chassis without the need for specialist contractors, reducing on-site work and costs. In some embodiments the inner wall member 26 is recessed in from the frame rear face to form a services open-faced cavity, and the frame provides a peripheral lip 44 around at least part of the inner wall panel 26. Advantageously, the modular construction system 10 allows for a variety of panel shapes, from rectangular to curved, allowing for multiple building designs. The accuracy of the chassis enables most other items related to "fitting-out" the building (internal finishes, cladding, etc.) to also be designed and cut by machines in factory conditions with millimetre tolerance. Panels include a service void with pre-cut slots 46 for "push-fit" M&E wiring and piping, further simplifying the construction process. In some embodiments the frame provides a peripheral lip 44 around the entire periphery of the inner wall panel. Advantageously, the modular construction system 10 is designed and engineered to be sustainable, circular economy, carbon negative, and zero waste. It is scalable and can be produced in a distributed network of micro factories for local production. The method of panel-to-panel connection enables insulation to be inserted in a controlled factory environment, rather than on-site, increasing the speed and simplicity of the build. In some embodiments cut-outs 46 are provided in the lip 44 to receive and support delivery of services such as electrical wires or water pipes. Advantageously, the cut-outs 46 in the lip 44 can comprise u-shaped slots to create a friction interface for receiving electrical wires or water pipes, or apertures for receiving and supporting these services. This further simplifies the installation process and ensures a secure and organized delivery of services within the modular construction system 10. In some embodiments the modular construction system 10 comprises panels 12 that form a substantially airtight hollow enclosure filled with insulation material. Advantageously, the airtight building envelope provided by the modular construction system 10 improves energy efficiency and reduces heat loss, contributing to the overall sustainability and eco-friendliness of the building. The panel-to-panel connection method also ensures that the insulation is inserted in a controlled factory environment, maintaining consistent quality and performance. In some embodiments, the frame and outer and inner wall members 24, 36 comprise both male 36 and female 38 joint parts that are cooperable with one another in use. This is more clearly shown in Figure 5. The frame and outer and inner wall members 24, 26 are rebated in the region of the male and female joint parts 36, 38, i.e., at the joint faces 32, such that the thickness of adjacent components is controlled at the joint faces 32. Advantageously, the incorporation of male and female joint parts 36, 38 in the frame and outer and inner wall members 24, 26 allows for a secure and precise connection between adjacent components, ensuring a consistent and accurate assembly of the modular construction system 10. The rebated joint faces 32 control the thickness of the panel components, addressing the issue of sheet material thickness variation, as discussed above. By controlling the thickness in the region of the joint faces 32, the modular construction system 10 can maintain critical external dimensions and provide accurate, predictable joints, regardless of the variation in material thickness between joined components. In some embodiments, the thickness at the joint faces 32 is 16mm. It will be appreciated that the thickness at the joint faces is selected dependent on the starting material thickness. For example, in the case of material that has a nominal thickness of 22mm, the thickness at the joint faces 32 may be reduced to 20mm, for example. Advantageously, by maintaining a consistent thickness at the joint faces 32, the modular construction system 10 can ensure a precise and secure connection between panels 12. This thickness control allows for the use of various construction-grade materials, such as plywood, OSB, and breathable alternatives, which may have inherent thickness variations. The controlled thickness of the panels 12 at the joint faces 32 also simplifies the design and manufacturing process, as it eliminates the need for time-consuming design recalibration and constant monitoring of material thickness. In some embodiments, the frame components each comprise at least one longitudinal slot 40 and the outer and inner wall member 24, 26 comprise at least one corresponding projection 42 on each of their longitudinal edges. The at least one projection 42 of the outer and inner wall members 24, 26 is received by the at least one slot 40 of the corresponding frame component. Advantageously, the use of longitudinal slots 40 and corresponding projections 42 provides a secure and accurate connection between the panels 12. This connection method ensures proper alignment and positioning of the panels 12 during assembly, contributing to the overall structural integrity and stability of the modular construction system 10. Additionally, the slot 40 and projection 42 design simplifies the assembly process, as it allows for easy and efficient panel-to-panel connections without the need for specialized tools or equipment. In some embodiments, the panel 12 further comprises a top 16 and a bottom 18, each of the top 16 and bottom 18 comprising at least one longitudinal slot therethrough 40, at least one lateral cut-out 38, and at least one projection 42 extending from the longitudinal edge thereof. The at least one longitudinal slot 40 receives a corresponding projection 42 of the outer and inner wall member 24, 26, the at least one lateral cut-out 38 receives a corresponding lateral projection 36 of a sidewall 14, and the at least one projection 42 is received by a corresponding rebate of the outer or inner wall member 24, 26. Advantageously, the inclusion of a top 16 and a bottom 18 with longitudinal slots 40, lateral cut-outs 38, and projections 36 allows for a comprehensive and secure connection between all components of the modular construction system. This design ensures proper alignment and positioning of the panels 12 during assembly, contributing to the overall structural integrity and stability of the system. The various connection methods also simplify the assembly process, as they allow for easy and efficient panel-to-panel connections without the need for specialized tools or equipment. In some embodiments, the panel 12 further comprises an intermediate member (not shown) extending between the outer wall member 24 and inner wall member 26 and being positioned centrally between the side walls 14. Advantageously, the inclusion of an intermediate member provides additional structural support and stability to the modular construction system 10. The intermediate member also contributes to the overall insulation and energy efficiency of the building, as it helps create a closed receptacle filled with insulation material. Furthermore, the intermediate member can assist in the organization and delivery of services within the building, such as electrical wiring and plumbing, by providing additional support and separation between the outer and inner wall members 24, 26. In some embodiments, the outer wall member 24 comprises a longitudinal groove (not shown) extending at least partially between opposing ends thereof for receiving an edge of the intermediate member. Advantageously, the longitudinal groove allows for a secure and precise connection between the outer wall member 24 and the intermediate member, ensuring that the overall structure maintains its critical external dimensions and stability. The groove also accommodates variations in sheet material thickness, such as those found in construction-grade plywood, OSB, and breathable alternatives, by providing a controlled thickness for the joint faces 32, as described in the present disclosure. The thickness of the joint faces 32 is controlled through application of a method of reducing the thickness of a panel 12 to control cumulative errors at joints. The method comprises the steps of cutting the length of the panel 12 to a pre-determined size, machining joining features into the panel 12, and rebating the panel 12 in the region of the joining features to control the thickness of the panel. Advantageously, this method ensures that the panel components are manufactured with millimetre accuracy using CNC technology from sheet materials, resulting in accurate, predictable joints, and preserving the critical external dimensions of the assembly. In some embodiments, the panel 12 has a thickness of between 17.5mm to 18.5mm. Advantageously, this range of thickness accommodates the natural variation in construction-grade sheet materials, such as plywood, OSB, and breathable alternatives, while still allowing for precise and secure connections between panels 12. In some embodiments, the joint faces 32 of the panel have a thickness of 16mm. Advantageously, this controlled thickness at the joint faces 32 ensures that joints fit perfectly and maintain the critical external dimensions of the assembly, regardless of the variation in material thickness, as described in the present disclosure. It will be appreciated by the person of skill in the art that various modifications may be made to the above-described examples without departing from the scope of the invention as defined by the appended claims. Although combinations of features are recited in the claims and / or disclosed in the specification, these combinations are not intended to limit the disclosure of various implementations. In fact, many of these features may be combined in ways not specifically recited in the claims and / or disclosed in the specification. Although each dependent claim listed below may directly depend on only one claim, the disclosure of various implementations includes each dependent claim in combination with every other claim in the claim set. No element, act, or instruction used herein should be construed as critical or essential unless explicitly described as such. Also, as used herein, the articles “a” and “an” are intended to include one or more items and may be used interchangeably with “one or more.” Further, as used herein, the article “the” is intended to include one or more items referenced in connection with the article “the” and may be used interchangeably with “the one or more.” Furthermore, as used herein, the term “set” is intended to include one or more items (e.g., related items, unrelated items, a combination of related and unrelated items, and / or the like), and may be used interchangeably with “one or more.” Where only one item is intended, the phrase “only one” or similar language is used. Also, as used herein, the terms “has,” “have,” “having,” or the like are intended to be open-ended terms. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. Also, as used herein, the term “or” is intended to be inclusive when used in a series and may be used interchangeably with “and / or,” unless explicitly stated otherwise (e.g., if used in combination with “either” or “only one of’).

Claims

1) A modular construction system comprising a plurality of building panels, each building panel comprising: a frame forming panel side walls, said frame providing a frame front face and a frame rear face; an outer wall member secured to the front face of the frame; and an inner wall member secured to the rear face of the frame, wherein the outer wall member includes cut-outs in predetermined positions whereby when two panel side walls abut, a cut-out of one panel is aligned with the cut-out of the other panel to receive a joining plate to join the two panels together, wherein each cut-out comprises pre-formed holes configured to concentrically align with preformed holes of the joining plate and wherein the joining plate is secured to the cutouts using bolts which screw into pre-inserted nuts in the pre-formed holes of the outer wall panels.01 10 242) A modular construction system according to claim 1, wherein the inner wall member is recessed in from the frame rear face to form a services open-faced cavity, said frame providing a peripheral lip around at least part of the inner wall panel.3) A modular construction system according to any of claims 1 or 2, wherein the frame provides a peripheral lip around the entire periphery of the inner wall panel.4) A modular construction system according to claim 3, wherein cut-outs are provided in the lip to receive and support delivery of services such as electrical wires or water pipes.5) A modular construction system according to claim 4, wherein the cut-outs comprise U-shaped slots to create a friction interface for receiving electrical wires or water pipes.6) A modular construction system according to claim 4, wherein the cut-outs comprise apertures for receiving and supporting electrical wires and water pipes.7) A modular construction system according to any preceding claim wherein each panel forms a substantially airtight hollow enclosure filled with insulation material.8) A modular construction system according to any preceding claim wherein each of the outer wall member and side walls comprise both male and female joint parts that are cooperable with one another in use, wherein the outer wall member and sidewalls are rebated in the region of the male and female joint parts such that the thickness of the outer wall member and sidewalls is controlled in the region of each of the male and female joint parts.01 10 249) A modular construction system according to claim 8, wherein the thickness of the outer wall member and sidewalls in the region of the male and female joint parts is 16mm.10) A modular construction system according to any preceding claim, wherein the sidewalls comprise at least one longitudinal slot therethrough and the inner wall member comprises at least one corresponding projection on each of its longitudinal edges, wherein the at least one projection of the inner wall member is received by the at least one slot of the side wall.11) A modular construction system according to claim 10, wherein the sidewalls comprise at least one projection extending from the longitudinal edge thereof and the outer wall member comprises at least one corresponding aperture in each of its longitudinal edges, wherein the at least one projection of the sidewall is received by the at least one aperture of the outer wall member.12) A modular construction system according to claim 11, wherein the panel further comprises a top wall and a bottom wall, each of the top wall and bottom wall comprising at least one longitudinal slot therethrough, at least one lateral cutout, and at least least one projection extending from the longitudinal edge thereof, wherein the at least one longitudinal slot receives a corresponding projection of the inner wall member, the at least one lateral cutout receives a corresponding lateral projection of01 10 24a sidewall, and the at least one projection is received by a corresponding rebate of the outer wall member.13) A modular construction system according to claim 12, wherein the panel further comprises an intermediate member extending between the outer wall member and inner wall member and being positioned centrally between the side walls.14) A modular construction system according to claim 13, wherein the outer wall member comprises a longitudinal groove extending at least partially between opposing ends thereof for receiving an edge of the intermediate member.15) A modular construction system according to claim 14, wherein each of the side walls comprises a longitudinal groove extending at least partially between opposing ends thereof for receiving an edge of the inner wall member.16) A building panel comprising: a frame forming panel side walls, said frame providing a frame front face and a frame rear face; an outer wall member secured to the front face of the frame; and an inner wall member secured to the rear face of the frame, wherein the outer wall member includes cut-outs in predetermined positions whereby when two panel side walls abut, a cut-out of one panel is aligned with the cut-out of the other panel to receive a joining plate to join the two panels together, wherein each cut-out comprises pre-formed holes configured to concentrically align with pre-formed holes of the joining plate and wherein the joining plate is secured to the cut-outs using bolts which screw into pre-inserted nuts in the pre-formed holes of the outer wall panels.

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