Support system

Abstract

The present invention provides a support frame for use in a system for supporting a horizontal slab, the support frame comprising a horizontal beam comprising a first corbel element on the first side face, the first corbel element comprising at least one corbel extending along at least a portion of the length of the horizontal beam between the first and second ends, the at least one corbel having a horizontal top surface; and at least two columns extending downwardly from the horizontal beam, said columns being spaced apart from each other; wherein said support frame being formed as a reinforced concrete unitary body. The present invention also provides a system for supporting a horizontal slab employing two or more support frames.

Description

SUPPORT SYSTEMFIELD OF THE INVENTION

[0001] The present invention pertains to the field of reinforced concrete modular structures.BACKGROUND

[0002] WO 2018 / 174825A1 discloses a method for constructing a pre-fabricated prefinished volumetric construction (PPVC) module for a building, the method comprising: (i) casting of concrete to form a body of the PPVC module, where the body of the PPVC module comprises one or more load-bearing columns and beams, and six walls including a roof that covers a top of the PPVC module; and (ii) substantially finishing an interior of the PPVC module before the PPVC module is transported to a site for assembly into a building.

[0003] US3568380 discloses a prefabricated building unit consisting of a prefabricated rectangular floor panel structure having prefabricated vertical load-bearing columns for attachment at each corner and at an intermediate region in the length of each side.

[0004] EP3498929A1 discloses a building module with a cuboid housing formed from a stackable, monolithic tubular body consisting of a concrete material, the four tubular walls of which form the floor, the ceiling and the side walls, wherein the door and the window are provided in the end walls.

[0005] WO2022 / 170430 discloses a pre-cast module formed from a horizontal rectangular or square slab having columns located at each corner of the slab. Multiple modules can be assembled together in parallel, perpendicular, or stacked arrangements, and any combination thereof, to form a larger structure.

[0006] When larger structures are constructed using two or more prefabricated modules in adjacent configuration, the available useful space within the structure can be determined by the open floor space within each individual module unimpeded by intervening walls and columns.

[0007] There is therefore a need for a simple system that can be used in conjunction with existing modular structures to provide large areas of space unimpeded by intervening walls and columns.

[0008] This background information is provided to reveal information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present invention.SUMMARY OF THE INVENTION

[0009] An object of the present invention is to provide a support system. In accordance with an aspect of the present invention, there is provided a support frame for use in a system for supporting a horizontal slab, the support frame comprising: a horizontal beam having a first end, a second end, a top face, a bottom face, first side face, and a second side face, the horizontal beam comprising a first corbel element on the first side face, the first corbel element comprising at least one corbel extending along at least a portion of the length of the horizontal beam between the first and second ends, the at least one corbel having a horizontal top surface; and at least two columns extending downwardly from the horizontal beam, said columns being spaced apart from each other; said support frame being formed as a reinforced concrete unitary body.

[0010] In accordance with another aspect of the present invention, there is provided a support system configured to support at least one horizontal slab, the support system comprising at least two supporting frames, each said supporting frame comprising: a horizontal beam having a first end, a second end, a top face, a bottom face, first side face, and a second side face, the horizontal beam comprising a first corbel element on the first side face, the first corbel element comprising at least one corbel extending along at least a portion of the length of the horizontal beam between the first and second ends, the at least one corbel having a top surface; and at least two columns extending downwardly from the horizontal beam, said columns being spaced apart from each other; each said support frame being formed respectively as a reinforced concrete unitary body; and a column connector assembly located at a bottom end of each of the first and second columns, the connector assembly being configured for attachment to a supporting surface, wherein each of said supporting frames is configured to support a respective end of the horizontal slab on the top surfaces of the at least one corbel of the respective first corbel elements.BRIEF DESCRIPTION OF THE FIGURES

[0011] Fig. 1 illustrates an isometric view of an embodiment of a one-sided support frame, suitable for use in a support system in accordance with the present invention.

[0012] Fig. 2 illustrates an isometric view of an embodiment of a two-sided support frame, suitable for use in a support system in accordance with the present invention.

[0013] Fig. 3 illustrates an isometric view of a footer support, suitable for use in a support system in accordance with the present invention.

[0014] Fig. 4 illustrates an isometric view of an exemplary implementation of a support system, of the present invention, in accordance with one embodiment.

[0015] Fig. 5 illustrates an isometric view of another exemplary implementation of a support system of the present invention, in accordance with one embodiment.DETAILED DESCRIPTION OF THE INVENTION

[0016] The term “corbel” is used to describe a horizontally oriented structure projecting from a vertical face which is configured to support a structure resting upon it.

[0017] As used herein, the term “about” refers to a + / -10% variation from the nominal value. It is to be understood that such a variation is always included in a given value provided herein, whether or not it is specifically referred to.

[0018] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0019] The present invention provides a support frame for use in a system for supporting a horizontal slab. The support frame comprises a horizontal beam having a first end, a second end, a top face, a bottom face, first side face, and a second side face, and at least two columns extending downwardly from the horizontal beam. The columns are spaced apart from each other.

[0020] In a preferred embodiment, the support frame is formed as a reinforced concrete unitary body.

[0021] In accordance with the present invention, the horizontal beam comprises a first corbel element on the first side face comprising at least one corbel extending along at least a portion of the length of the horizontal beam between the first and second ends. The corbel element has a horizontal top surface configured to support an edge of a horizontal slab,

[0022] The present invention further provides a support system configured to support at least one horizontal slab, the support system comprising at least two of the reinforced concrete support frames of the present invention.

[0023] In a preferred embodiment, the support frame comprises a horizontal beam having a first column extending downwardly from the first end of the beam and a second column extending downwardly from the second end of the beam. The horizontal beam comprises a first corbel element on a first side / vertical face of the beam.

[0024] The support system of the present invention can be used in conjunction with any building construction system, including modular systems. The support system is employed, for example, by placing a first support frame against an existing building structure in abutting arrangement and a second support frame against another existing building structure in abutting arrangement.

[0025] In accordance with the present invention, each of the supporting frames is configured to support a respective end of a horizontal slab on a top surface of the corbel elements when the respective horizontal beams are provided in parallel arrangement.

[0026] The two support frames can be therefore used to support a slab structure on their respective corbel elements, thereby providing a covered space between the two building structures. This covered space can increase the available useful space within the structure, and can increase the unimpeded distance and area between walls and / or columns.

[0027] In one embodiment, the first corbel element comprises at least one corbel extending along at least a portion of the length of the horizontal beam between the first and second ends. In one embodiment, the first corbel element comprises one corbel that extends the entire length of the horizontal beam. In another embodiment, the corbel element comprises multiple corbels distributed at intervals along the length of the horizontal beam.

[0028] The support system can be installed onto any suitable supporting surface, such as a concrete slab, a concrete footer support structure, or the like.

[0029] In order to facilitate attachment to the supporting surface, the support system is provided with a column connector assembly located at a bottom end of each of the first and second columns of the unitary support body. The connector assembly may be used to attach directly to the supporting surface or to a corresponding connector assembly installed on the supporting surface.

[0030] In one embodiment, where the supporting surface is a footer support, the footer support is provided with footer connector assemblies located on its top surface, which are each configured to receive a respective column connector assembly located at the bottom of each column.

[0031] In one embodiment, the support frame is a two-sided support frame provided with two corbel elements. In this embodiment, in addition to the first corbel element on the first side / vertical face of the horizontal beam, a second corbel element is provided on the second side / vertical face of the horizontal beam. In one embodiment, the second corbel element comprises at least one corbel extending along at least a portion of the length of the horizontal beam between the first and second ends. In one embodiment, the second corbel element comprises one corbel extending the entire length of the horizontal beam.

[0032] In one embodiment of a two-sided support frame, the top surfaces of both corbel elements are at the same height on the horizontal beam. In one embodiment of a two-sided support frame, the top surfaces of the first and second corbel elements are at different heights on the horizontal beam.

[0033] The two-sided support frame can be used as a central support in combination with two one-sided support frames to support two horizontal slabs in sequence. In such a configuration, each of the one-sided support frames is configured to support one end of a first and second horizontal slab, respectively, while the two-sided frame is provided between the first and second slabs to support the opposite end of each of the first and second slabs. It is within the scope of the present invention to use multiple two-sided support frames in sequence between two one-sided support frames located at the ends of the overall structure.

[0034] The use of the three or more support frames can increase the unimpeded distance and area between walls and / or columns.

[0035] In one embodiment, the support frames comprise a cast-in attachment element located in the top face of the horizontal beam adjacent the first and second ends of the horizontal beam. This cast-in attachment at the top of the columns can be used to installconnector element, wherein each connector element is configured to connect to a corresponding bottom connector element on another support frame stacked above.

[0036] The support frames of the present invention can be used in conjunction with the building modules as disclosed in WO2022 / 170430, entitled “Module for Use in Preparing a Prefabricated Structure, Method for Manufacturing Same and Transport Frame”, the disclosure of which is incorporated herein by reference in its entirety. The support frames of the present invention can be sized to match the dimensions of the adjacent building modules to provide a seamless transition between the upper surface of the building module and the adjacent horizontal slab(s) being supported by the support frames.

[0037] The footer supports of the present invention can also be sized to match the dimensions (height) of the surface provided to support the building modules, to provide a seamless transition. In one embodiment, the surface provided to support the building modules is a precast base such as that disclosed in US 63 / 597,936 entitled “Precast Concrete Base”, the disclosure of which is incorporated herein by reference in its entirety.

[0038] In one embodiment, the support frames are provided with service access openings of suitable size and shape to provide service access and / or to receive utility infrastructure.

[0039] The invention will now be described with reference to specific examples. It will be understood that the following examples are intended to describe embodiments of the invention and are not intended to limit the invention in any way.

[0040] Fig. 1 depicts a one-sided support frame 100, formed as a unitary body comprising a horizontal beam 13 having two columns 11 and 12, each extending downwardly from opposing ends of beam 13. In the embodiment shown in Fig. 1 , beam 13 is provided with corbel 15, extending the entire length of a first side / vertical face of the beam and which is configured to support a body (not shown) resting on a top surface of the corbel.

[0041] Fig. 2 depicts a two-sided support frame 200, formed as a unitary body comprising a horizontal beam 23 having two columns 21 and 22, each extending downwardly from opposing ends of beam 23. In the embodiment shown in Fig. 2, beam 23 is provided with two corbels 25a and 25b, extending the entire length of the two side / vertical faces of the beam and which is configured to support bodies (not shown) resting on a top surface of the corbels.

[0042] Fig. 3 depicts a footer support 300, suitable for use in a support system in accordance with the present invention. In the embodiment shown, footer support 300 isformed with a wide base 33 for increased stability when acting as the supporting surface for support frames (not shown). Footer support 300 has footer connector assemblies 39, located at each end of the top surface of the footer support, the footer connector assemblies 39 being configured to receive corresponding column connector assemblies located on respective columns of the support frame (not shown).

[0043] Figs. 4 and 5 depict examples of structures employing the support system of the present invention. These embodiments illustrate the use of the support system in combination with pre-cast modules as disclosed in WO2022 / 170430, the disclosure of which is incorporated herein by reference in its entirety.

[0044] As shown in Fig. 4, two precast concrete modules 50 are mounted on respective precast foundations 60, via module connector assemblies 59, located at the bottom of each leg of the module, connected to respective foundation connector assemblies 69.

[0045] Located adjacent to each of the modules is a respective one-sided support frame 100, each of which is mounted on a respective footer support 300. Extending between the two support frames 100, is horizontal slab 70, such that each opposing end of slab 70 is resting on respective corbels 15 of the support frames 100.

[0046] The structure shown in Fig. 5 differs from the structure depicted in Fig. 4 through presence of two horizontal slabs 70 supported by a centrally disposed two-sided support frame 200. As with the embodiment shown in Fig. 4, a one-sided support frame 100 is located adjacent to each of the modules, each support frame 100 being mounted on a respective footer support 300. One end of each horizontal slab 70 rests on respective corbels 15 of the outer one-sided support frames 100, while the other end of each slab rests on respective corbels 25a and 25b of central support frame 200.

[0047] It is obvious that the foregoing embodiments of the invention are examples and can be varied in many ways. Such present or future variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.

Claims

WE CLAIM:

1. A support frame for use in a system for supporting a horizontal slab, the support frame comprising: a horizontal beam having a first end, a second end, a top face, a bottom face, first side face, and a second side face, the horizontal beam comprising a first corbel element on the first side face, the first corbel element comprising at least one corbel extending along at least a portion of the length of the horizontal beam between the first and second ends, the at least one corbel having a horizontal top surface; and at least two columns extending downwardly from the horizontal beam, said columns being spaced apart from each other; said support frame being formed as a reinforced concrete unitary body.

2. The support frame of claim 1 , wherein said at least two columns comprises: a first column extending downwardly from the first end of the horizontal beam; and a second column extending downwardly from the second end of the horizontal beam.

3. The support frame of claim 1 , wherein the first corbel element comprises one corbel that extends the entire length of the horizontal beam.

4. The support frame of any one of claims 1 to 3, further comprising a second corbel element on the second side face of the horizontal beam, the second corbel element comprising at least one corbel extending along at least a portion of the length of the horizontal beam between the first and second ends.

5. The support frame of claim 4, wherein the second corbel element comprises one corbel that extends the entire length of the horizontal beam.

6. The support frame of claim 4 or 5, wherein the top surfaces of the first and second corbel elements are at the same height on the horizontal beam.

7. The support frame of claim 4 or 5, wherein the top surfaces of the first and second corbel elements are at different heights on the horizontal beam.

8. The support frame of any one of claims 1 to 7, further comprising a column connector assembly located at a bottom end of each of the first and second columns, the connector assembly being configured for attachment to a supporting surface.

9. The support frame of any one of claims 1 to 8, further comprising a cast-in attachment element located in the top face of the horizontal beam adjacent the first and second ends of the horizontal beam.

10. The support frame of claim 9, wherein each said cast-in attachment element is configured to receive a connector assembly configured for attachment to another support frame arranged in a vertical stacked configuration.11 A support system configured to support at least one horizontal slab, the support system comprising: at least two reinforced concrete support frames, each said support frame comprising: a horizontal beam having a first end, a second end, a top face, a bottom face, first side face, and a second side face, the horizontal beam comprising a first corbel element on the first side face, the first corbel element comprising at least one corbel extending along at least a portion of the length of the horizontal beam between the first and second ends, the at least one corbel having a top surface; and at least two columns extending downwardly from the horizontal beam, said columns being spaced apart from each other; each said support frame being formed as a reinforced concrete unitary body; and a column connector assembly located at a bottom end of each of the first and second columns, the connector assembly being configured for attachment to a supporting surface, wherein each of said at least two support frames is configured to support a respective end of the horizontal slab on the top surfaces of the at least one corbel of the respective first corbel elements.

12. The support system of claim 11 , wherein the at least two columns comprises: a first column extending downwardly from the first end of the horizontal beam; and a second column extending downwardly from the second end of the horizontal beam.

13. The support system of claim 11 or 12, wherein the first corbel element comprises one corbel that extends the entire length of the horizontal beam.

14. The support system of any one of claims 11 to 13, further comprising a footer support, the footer support being configured to receive each of the column connector assemblies on a respective footer connector assembly located on a top surface of the footer support, wherein the footer support acts as the supporting surface.

15. The support system of any one of claims 11 to 14, further comprising a second corbel element on the second side face of the horizontal beam, the second corbel element comprising at least one corbel extending along at least a portion of the length of the horizontal beam between the first and second ends.

16. The support system of claim 15, wherein the second corbel element comprises one corbel that extends the entire length of the horizontal beam.

17. The support system of claim 15 or 16, wherein the top surfaces of the first and second corbel elements are at the same height on the horizontal beam.

18. The support system of claim 15 or 16, wherein the top surfaces of the first and second corbel elements are at different heights on the horizontal beam.

19. The support system of any one of claims 11 to 18, further comprising a cast-in attachment element located in the top face of the horizontal beam adjacent the first and second ends of the horizontal beam.

20. The support system of claim 19, wherein each said cast-in attachment element is configured to receive a respective connector assembly configured for attachment to another support frame.

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