Construction system for prefabricated modules with truss structure clad in aluminium composite

Abstract

The present invention pertains to the construction industry and, more specifically, relates to a construction system for modules having an internal structure made from aluminium trusses that are externally and internally clad with ACM (aluminium composite material), and having rock wool panels and electrical and hydraulic connections between the external and internal cladding, wherein each module is designed for assembly and disassembly as needed, providing practicality while ensuring aesthetic appeal and attractiveness.

Description

[0001] CONSTRUCTION SYSTEM OF PREFABRICATED MODULES WITH A TRUSS STRUCTURE COVERED WITH COMPOSITE ALUMINUM Technological Sector of the Invention

[0002]

[0001] The present invention belongs to the civil construction sector, and refers, more specifically, to a construction system of modules with an internal structure of aluminum trusses, coated externally and internally with ACM (composite aluminum) and between the coatings it has rock wool plates, and electrical and hydraulic connections; each module is designed to be assembled and disassembled when necessary, having practicality that guarantees aesthetics and beauty.

[0003] State of the art

[0004]

[0002] Prefabricated module building systems are a form of construction that uses prefabricated units or modules that are manufactured in a factory or other location off-site and then transported and assembled at the desired location. These modules are designed in parts and these are attached to complete the structure.

[0005]

[0003] There are different types of prefabricated modules, from simple modules used to build temporary structures to complex modules that can be stacked and interconnected to create multi-story buildings. These modules can be manufactured from a variety of materials, such as wood, concrete, steel, and even reinforced plastic.

[0006]

[0004] One of the main advantages of prefabricated module construction systems is the speed of construction. Because the modules are manufactured in advance, the time required for on-site construction is significantly reduced. Furthermore, construction quality is generally better because the modules are manufactured under controlled factory conditions, where rigorous quality controls can be implemented.

[0007]

[0005] Another advantage is flexibility. Prefabricated modules can be designed and manufactured according to specific project needs, allowing for a wide variety of configurations and layouts. Furthermore, they can be easily disassembled and reassembled at another location, making them a suitable option for temporary structures or for projects that may need to be relocated in the future.

[0008]

[0006] Prefabricated modular construction systems are also considered more sustainable compared to traditional construction methods. Manufacturing in a controlled environment reduces material waste, and rapid assembly reduces negative impacts on the construction site and surrounding community.

[0009]

[0007] However, it's important to note that prefabricated module construction systems also present challenges. The logistics of transporting modules to the construction site can be complex, especially for projects in remote areas. Furthermore, customization of modules can be limited, as they are mass-produced.

[0010]

[0008] Despite these challenges, prefabricated modular construction systems have gained popularity due to their advantages in terms of speed, quality, flexibility, and sustainability. They are frequently used in residential, commercial, and industrial projects, offering an efficient and modern alternative to traditional construction methods.

[0011]

[0009] Some technical solutions are known from patent documents, such as W02020124181, which was a pioneering project linked to the present invention and which reveals prefabricated modules with sandwich-type metal panels with polyurethane thermo-acoustic insulation and incorporated electrical, hydraulic and sewage installations, corresponding to a modular construction system, with a pentagonal shape and preferred dimensions equal to 28.56 m 2, which are characterized by being manufactured through a chassis covered by one-piece panels from the roof to the base, containing between the metal panels, expanding polyurethane foam, with thermo-acoustic and fire-resistant function, of specific thickness, and its one-piece structure serves as a technical area, using the walls of the module for the passage of hydraulic and electrical pipes and at the base the sanitary system of the prefabricated module is distributed, comprising inspection boxes, grease trap and a sewage treatment plant or ETE, waterproofing is carried out with polyurethane, where the module receives two layers of primer and paint is applied, which is polyurethane, finally the roof has a gutter to capture rainwater, as well as an opening with a pergola, for ventilation by temperature difference.

[0012]

[0010] This module, disclosed in WO2020124181, consists of metal panels coated with polyurethane, with all the facilities incorporated, produced from a chassis. In contrast, in the present patent now disclosed, the module is made of lattice pieces, in which the lattices form sections, and each section forms the module's parts: sides, floor, roof, and back. There is no built-in network. For its safety, the electrical and hydraulic connections pass through the module but are connected directly to the network or external system. The coating of the present patent is made of aluminum composite material (ACM) and rock wool, being safer and more resistant than polyurethane. The solar energy system is already included in the module, and the floor is made of PVC panels. Furthermore, the difference is evident when observing that the present module is not based on a single chassis and is assembled only with metal panels, but is made in pieces and in sections.

[0013]

[0011] In WO2020124181 it is not possible to assemble and disassemble, because it has a fixed characteristic (aluminum coating was anchored to the trusses), it does not allow transportation in parts nor the assembly in situ of the modules, increasing the price of the product and making its sale and commercialization difficult. The module system now disclosed in the invention can be presented with the sections disassembled, up to 5 modules of 47m 2 in a 20-foot container, making them easier to transport and sell. These modules have straighter, narrower, and more rounded corners, and the units have internal areas of 12m². 2 , 27m 2 or 49m 2The structural parts are designed to accommodate all three modules, reducing the number of sections if the structure is larger or smaller.

[0012] The type of fastening disclosed in the invention allows for the assembly and disassembly of sections, allowing the module to be transported in parts, all within a container. Removal of the module is convenient and can be performed by a trained team using the appropriate equipment, making the module easily assembleable, disassembleable, or removable.

[0014]

[0013] Notwithstanding, another relevant document is EP3358096, which discloses a prefabricated module with sandwich-type metal panels with polyurethane thermal and acoustic insulation, and electrical, hydraulic and sewage installations incorporated, composed of a prefabricated module built on a metal structure covered by solid metal panels, the panels are filled with polyurethane foam with the function of thermal and acoustic insulation of the module in question. Document US9631365 discloses construction modules including a structure composed of corner support posts, bottom rails and top rails, wall panels, windows and a door.

[0015] Novelties of the Invention

[0016]

[0014] In this context, the present invention presents a structure made of aluminum trusses, which allows the mold to be assembled and disassembled. Regarding the cladding, the use of aluminum composite material (ACM) for external and internal walls provides the durability and protection (flame retardant) that a home or work environment requires. And the rock wool cladding provides part of the thermal comfort necessary for living in a cold or hot environment. Regarding ventilation, the windows and door offer direct and indirect ventilation. Above the module, the air intake allows the exchange of hot air, and because the module is suspended from the ground, there is ventilation underneath the module, allowing for cooling as a whole.

[0017]

[0015] This results in faster construction and faster delivery; the materials, manufacturing process, and scaled production ensure significant cost reductions for module production; and the materials used are durable and recyclable, ensuring a long service life.

[0016] Transporting an entire module is expensive, hinders marketing, and prevents the assembly of modules in different, larger, or customized sizes. Another issue is that the sections are designed and formatted for each type of module—commercial, residential, or hospital. This changes the positioning of electrical and plumbing networks, as well as the cladding.

[0018]

[0017] The coating is covered with rock wool panels, which are infinitely safer and better than polyurethane, easy to apply, guarantee thermal and acoustic insulation and do not harm or pollute the environment.

[0019]

[0018] As the structure is made of lattice, in parts, the same piece of structure can be used to form internal areas of 12m 2 , 27m 2 or 49m 2 This allows for increased truss production and makes it easier to assemble and section the sections.

[0020]

[0019] This increases production speed and simplifies the assembly process from start to finish. All trusses are sent to the factory warehouse, where the aluminum composite panel (ACM)-clad sections are assembled. The windows and connections are located on the sides of the module, while the rear wall serves as a closure. These modifications result in a more practical and agile module to produce. They also allow for more transportation in less space, ensuring worldwide sales.

[0021] Description of the attached drawings

[0022]

[0020] In order for the present invention to be fully understood and put into practice by any technician in this technological sector, it will be described in a clear, concise and sufficient manner, based on the attached drawing, which illustrates and subsidizes it, listed below:

[0023] Figure 1 represents the perspective view of an assembled structure;

[0024] Figure 2 represents the side view of a detailed structure;

[0025] Figure 3 represents the side view of the floor, wall and ceiling details;

[0026] Figure 4 represents the perspective view of the lining units;

[0027] Figure 5 represents the perspective view of the floor units;

[0028] Figure 6 represents the perspective view of the wall units; Figure 7 represents the perspective view of the ceiling units.

[0029] Detailed Description of the Invention

[0030]

[0021] The present invention presents a structure supported by metal trusses (TL) that are joined to modules, which are formed by lining units (FR) with a length between 1.90 and 2.40m and a width between 1.00 and 1.50m, floor units (PS) with a length between 1.00 and 1.50m and a width between 1.20 and 1.50m, wall units (PR) with folds at the ends having a height of 2.34m and a width between 1.00 and 1.50m, lining units (FF) with one end with folds with a height of 2.30m and a width between 1.00 and 1.50m; in which the floor units (PS) are covered above their structure by composite aluminum (ACM) and traditional cladding (RV); the ceiling (FR)(FF) and wall (PR) units, when assembled together with the trusses, receive electrical (ET) and hydraulic (HD) connections and, on the inside, rock wool (LR) and aluminum composite (ACM) coating, aiming at thermal and acoustic comfort, and may have tiles for wet areas.

[0031]

[0022] Preferably, the construction system has 4 lining units (FR) with a length of 2.40m and a width of 1.50m, 1 unit (FR) with a length of 2.40m and a width of 1.20m, 1 unit (FR) with a length of 2.40m and a width of 1.00m, 4 units (FR) with a length of 1.90m and a width of 1.50m, 1 unit (FR) with a length of 1.90m and a width of 1.20m, 1 unit (FR) with a length of 1.90m and a width of 1.00m; 2 floor units (PS) with a length of 1.50m and a width of 1.20m, 8 units (PS) with a length of 1.50m and a width of 1.50m, 2 units (PS) with a length of 1.27m and a width of 1.20m, 8 units (PS) with a length of 1.27m and a width of 1.50m, 2 units (PS) with a length of 1.00m and a width of 1.50m, 2 units (PS) with a length of 1.00m and a width of 1.27m;8 wall units with folds at the ends (PR) with a height of 2.34m and a width of 1.50m, 2 units (PR) with a height of 2.34m and a width of 1.20m, 2 units (PR) with a height of 2.34m and a width of 1.00m; 4 ceiling units with one end with folds (FF) with a height of 2.30m and a width of 1.50m, 1 unit (FF) with a height of 2.30m and a width of 1.20m, and 1 unit (FF) with a height of 2.30m and a width of 1.00m.;

[0032]

[0023] A TIG-welded 6351 T6 structural aluminum alloy truss frame consisting of 40mm x 40mm main tubes with a thickness of 3.2mm and 25mm x 25mm trusses with a thickness of 2mm is recommended. The trusses are 200mm x 200mm squares with various lengths that are boltable modules with 3 / 8" carriage bolts.

[0033]

[0024] After the structure, the module receives rock wool (LR) throughout the walls (PR) and lining (FR)(FF), totaling 129m 2of rock wool, each plate being 4.00mm long, 1.20m wide, 32 to 64kg / m 3 in density and 25 to 100 mm thick, a material made of fiber extracted from special basalt rocks and other minerals with a durability of approximately 50 years. The rock wool will be used for acoustic insulation and also thermal insulation of the module.

[0034]

[0025] The internal and external finishing is done using composite aluminum plates (ACM), being 174.44m 2 of internally composed aluminum and 132m 2 Externally. Aluminum composite material (ACM) is a type of high-strength aluminum cladding consisting of a polyethylene core sandwiched between two tensioned aluminum sheets. It offers high durability and strength, and each sheet measures 50m wide by 1.5m long.

[0035]

[0026] The module may serve several purposes, depending on the user's needs, such as commercial, residential, business, among others.

[0036]

[0027] Each module is produced in parts (units). These parts are the same and allow for the assembly of three module sizes, that is, to obtain internal areas of 12, 27 or 49m 2The difference lies in the truss manufacturing and assembly process, with the sections being able to be assembled and disassembled during the manufacturing process.

[0028] The module not only has a chassis and metal cladding panels, making it robust, but also has a structure that provides greater weather resistance and greater stability and comfort for those inside.

[0029] The floor, like the entire module, also has sections (assembleable truss parts that, when joined together, form the module), which helps distribute the load and ensures a feeling of stability for those inside. This is an improved module, designed to be transported, assembled, and disassembled. It is easy to mobilize and demobilize. Despite being heavy and resistant, it is versatile and can solve various problems, from housing, clinics, businesses, and cafeterias to emergency services.

[0037]

[0030] It also has tiles on the interior walls that must be washable, such as the bathroom and kitchen at a minimum height of 1.20 m. And the electrical installations will be done in accordance with Brazilian regulatory standards, as will the water and sewage pipes. And the installed frames will be made of aluminum and glass, and the interior doors will be made of wood.

[0038]

[0031] It is important to emphasize that the figures and descriptions provided do not have the power to limit the forms of execution of the inventive concept proposed herein, but rather to illustrate and make understandable the conceptual innovations revealed in this solution. Therefore, the descriptions and images must be interpreted in an illustrative and not limitative manner, and there may be other equivalent or analogous forms of implementation of the inventive concept disclosed herein that do not escape the spectrum of protection outlined in the proposed solution.

Claims

CLAIMS 1- CONSTRUCTION SYSTEM OF PREFABRICATED MODULES WITH TRUSS STRUCTURE COVERED WITH COMPOSITE ALUMINUM characterized by comprising a structure supported by metal trusses (TL) that are joined to modules, which are formed by lining units (FR) with a length between 1.90 and 2.40m and a width between 1.00 and 1.50m, floor units (PS) with a length between 1.00 and 1.50m and a width between 1.20 and 1.50m, wall units (PR) with folds at the ends having a height of 2.34m and a width between 1.00 and 1.50m, lining units (FF) with one end with folds with a height of 2.30m and a width between 1.00 and 1.50m; in which the floor units (PS) are covered above their structure by aluminum composite (ACM) and traditional cladding (RV);the lining (FR)(FF) and wall (PR) units when assembled together with the trusses (TL) receive the electrical (ET) and hydraulic (HD) connections and for the internal side rock wool (LR) and aluminum composite (ACM) coating.; 2- CONSTRUCTION SYSTEM OF PREFABRICATED MODULES WITH TRUSS STRUCTURE COVERED WITH COMPOSITE ALUMINUM, according to claim 1, and characterized by preferably having 4 lining units (FR) with a length of 2.40m and a width of 1.50m, 1 unit (FR) with a length of 2.40m and a width of 1.20m, 1 unit (FR) with a length of 2.40m and a width of 1.00m, 4 units (FR) with a length of 1.90m and a width of 1.50m, 1 unit (FR) with a length of 1.90m and a width of 1.20m, 1 unit (FR) with a length of 1.90m and a width of 1.00m; 2 floor units (PS) with a length of 1.50m and a width of 1.20m, 8 units (PS) with a length of 1.50m and a width of 1.50m, 2 units (PS) with a length of 1.27m and a width of 1.20m, 8 units (PS) with a length of 1.27m and a width of 1.50m, 2 units (PS) with a length of 1.00m and a width of 1.50m, 2 units (PS) with a length of 1.00m and a width of 1.27m;8 wall units with bends at the ends (PR) with a height of 2.34m and a width of 1.50m, 2 units (PR) with a height of 2.34m and a width of 1.20m, 2 units (PR) with; height of 2.34m and width of 1.00m; 4 lining units with one end with folds (FF) with height of 2.30m and width of 1.50m, 1 unit (FF) with height of 2.30m and width of 1.20m, and 1 unit (FF) with height of 2.30m and width of 1.00m.

Images