US20050076605A1

US20050076605A1 - Self-supporting framework modular structure

Info

Publication number: US20050076605A1
Application number: US10/498,811
Authority: US
Inventors: Enrico Giaconi
Original assignee: Individual
Current assignee: Individual
Priority date: 2001-12-21
Filing date: 2002-12-23
Publication date: 2005-04-14
Also published as: EP1458940A1; CN1606651A; AU2002353399A1; CN1300422C; EP1321592A1; WO2003054314A1

Abstract

A method to provide a self-supporting pre-fabricated structure framework, for the building industry, comprising main uprights (3) formed by extruded sections having outside a plurality of longitudinal grooves (3′), in which connecting elements (5,6,7) are put at predetermined knots. Each connecting element (5,6,7) has a first portion (13), that engages and locks into one of the grooves (3′), and a second portion (13′) that protrudes from said groove (3′). The main uprights (3) are connected to each other through the use of main girders (4) having outside a plurality of longitudinal grooves (4′) in which engage said second portions (13′) of said connecting elements (5,6,7) engage and are locked. Further uprights (14,14 a) and/or secondary girders (15) can be connected having the same width of said uprights (3) and main girders (4). The application of supporting modular external and inner boards (20) is provided having inside flanged elements that engage the main uprights (3) and are connected to said main girders (4) at the top and the bottom end.

Description

FIELD OF THE INVENTION

The invention described below refers to a method for making a self-supporting framework structure, like that of a pre-fabricated building for use as house, office, emergency dwelling, dormitory, mess-room, warehouse etc.
The invention has also the object to obtain a modular structure, by using extruded sections, supporting boards and fastening them to one another; this structure can be used, for example, to make pre-fabricated buildings.
Furthermore, the invention relates to a quickly releasable connecting and locking device that allows to carry out this method, for joining the extruded sections of the structure and the supporting boards applied to them.

BACKGROUND OF THE INVENTION

A pre-fabricated building can be made quickly, such as a house, office, emergency dwelling, dormitory, mess-room etc.
The particular flexibility of a pre-fabricated structure allows both a lasting and a temporary use. Furthermore, the construction method is suitable to be executed quickly because it is a ready solution with direct installation. According to the needs, the rooms of a pre-fabricated building can be changed, enlarged or removed and used in other places.
The technique of production and of construction of pre-fabricated structures, however, has presently some limitations if modular and ready to make solutions are required.
In fact, the existing pre-fabricated buildings, used as houses, are made almost completely of wood even if they are assembled by means of metal carpentry.
This causes a pre-fabricated structure to be expensive and requiring a lot of work of specialized workers.
A prefabricated structure is known from U.S. Pat. No. 4,073,113 obtained by assembling rolled profiled sections by means of L-shaped junction elements. The profiled sections have wide grooves with a bent edge bent that creates an undercut portion. The junction elements are associated to two elongated anchor inserts which, suitably oriented with an edge parallel to a groove, can be put into two respective grooves that have orthogonal axes. Once in, the anchor inserts can be rotated of 90° and tightened in the respective groove against the junction element. The tightening action buckles the edges bent of the grooves.
This structure has the drawback that the junction elements remain outside the grooves. Furthermore, the deformation of the locked edges does not allow the profiled section to be disassembled and then used again, unless replacing the profiled section. Furthermore, very wide grooves are necessary for allowing the rotation of the anchor inserts. Finally, it is not possible, using the same grooves, to wall of the apertures of the structure.

SUMMARY OF THE INVENTION

It is therefore object of the present invention to provide a method for making a self-supporting framework structure, for example a pre-fabricated one, that does not present the drawbacks of the known systems.
It is another object of the present invention to provide a method for making a modular structure, by fastening to each other extruded sections and self-supporting boards, and that allows, with respect to the prior art, to obtain a structure that is light, strong, easy and quick to assemble.
It is a particular object of the invention to provide connecting elements for joining steadily and quickly two or more sections and/or supporting boards so that they become integral to each other, and the connecting elements sink within the extruded sections.
According to a first aspect of the invention, a method to provide a self-supporting pre-fabricated framework structure provides the steps of:

- pre-arranging a plurality of main uprights in the form of slotted section rods having outside a plurality of longitudinal grooves;
- arranging connecting elements at predetermined knots on the main uprights characterised by having each a first portion that engages and locks into said grooves and a second portion that protrudes from them;
- connecting transversally the main uprights to each other at the previously arranged knots, through the use of main girders having outside a plurality of longitudinal grooves in which the second portions of the connecting elements engage and are locked, wherein said connecting elements sink within said grooves.

Advantageously, the application is provided of further secondary girders and/or uprights having respectively the same width of said main uprights and girders.
In particular, the secondary uprights have the same height as the distance between two consecutive main girders, whereas the secondary girders have the same length as the distance between two consecutive main uprights. Preferably, the secondary uprights and/or girders have such a profile to snap-engage in the grooves of the main girders and uprights, unimpeded by the connecting elements. Alternatively, said connecting elements are used for the connection of said secondary uprights and/or girders with said main girders and uprights.
Once the framework structure according to the invention is formed by the main and secondary uprights and girders, modular external supporting boards are applied to the framework structure. Furthermore, the supporting boards have inside flanged elements that engage the main or secondary uprights along their longitudinal edges and also fit the girders at their top and bottom ends.
Preferably, a basement is pre-arranged comprising a plurality of anchorages for said main uprights, which form the supporting uprights of the structure, and then the connection of the main uprights on said anchorages creating said main uprights.
Advantageously, the anchorages prepared in the basement are in the form of fastening protruding elements from the basement same. Such protruding elements have cross section equal and complementary to the inner channel of the main uprights, whereby their connection to the main uprights is carried out simply, introducing the uprights on the protruding elements and blocking it with bolts.
The main uprights are connected to the main girders, as above said, by connecting elements. Preferably, each connecting element is formed by at least two orthogonal rods integral to each other. Each rod has cross section capable of engaging the profiled groove of the uprights and/or main girders and each of them can be fastened in a quickly releasable way in the grooves of the girders and of the main uprights.
Advantageously, several types of connecting elements are provided, according to the different needs of the structure according to the invention. In fact, for example, for making a peaked roof, oblique girders are provided that engage with the upper ends of the main uprights. In this case, the connecting elements have the first portion that moves vertically in a respective groove of the upright, whereas the second portion is bent at an angle, respectively acute or obtuse, depending on the upward or downward portion of the oblique girder with respect to the knot. Concerning, instead, the connection of two oblique girders at the peak of the roof, connecting elements are provided that have a first and a second portion engaging the respective grooves of said two girders. In case of joining a main upright and a short section having vertical axis, the connecting elements have the first portion that is arranged vertically in a respective groove of the main upright, whereas they have a second portion parallel to the first portion, but shifted from it, which is arranged in the groove of said short section.
The peculiarity of the structures according to the invention is flexibility, that allows both a lasting and temporary use; the construction method is quick to carry out because the structural elements are ready to use and of direct installation.
A pre-fabricated made with the method according to the present invention can be adapted according to the place and climate with safety and high comfort.

BRIEF DESCRIPTION OF THE DRAWINGS

Further characteristics of the device according to the present invention, will be made clearer with the following description of an embodiment thereof, exemplifying but not limitative, with reference to the attached drawings, wherein:
FIG. 1 shows a diagrammatical elevational view of a pre-fabricated building executed with a structure according to the invention;
FIGS. 2A and 2B, show respectively a plan view from below of the structure of FIG. 1, and a cross sectional enlarged view of the foundation, wherein are shown the fastening elements for main uprights of the structure;
FIGS. 3A, 3B, show respectively the sections of an upright and of a main girder;
FIG. 3C shows an embodiment of the main girder of FIG. 3B with fastening wings for supporting boards;
FIGS. from 3D to 3E show respectively the sections of a secondary upright and secondary girder;
FIGS. from 3F, 3G and 3K, show the sections of three different auxiliary uprights;
FIG. 3H shows in cross section a secondary girder, that can be fixed to the main uprights with connecting elements;
FIG. 3L shows a cross section of a main upright for internal partition of the building;
FIGS. 4A, 4B show a cross section according to a plane horizontal a fastening step of inner and external supporting boards to the main uprights and/or to auxiliary uprights added to the main uprights, respectively at the union knots indicated respectively with IV-A and IV-B of FIG. 2A;
FIGS. 5A and 5B show respectively a top plan and a perspective view of a cross connecting element for fastening a main upright to a main girder;
FIGS. 6A, 6B, 6C, 7, 8 and 9 show other types of connecting elements, used for fixing the uprights to the girders;
FIG. 10 shows a perspective view of the fastening step of a main upright to a main girder;
FIGS. 10A and 10B show an elevational cross sectional view of a main upright and of different main girders of various heights,
FIG. 10C shows an elevational cross sectional view of a main upright and of different main girders of various heights with union of the supporting boards;
FIG. 10D shows the view of figure 10C with the addition of a secondary girder;
FIGS. 11 and 12 show a partial elevational view of the zone of union of the structure at the points of the roof peak indicated respectively with XI and XII in FIG. 1;
FIGS. 13 and 14 show a sectional view respectively of an embodiment having triangular profile of an extruded section according to the invention and of an upright formed by main uprights according to FIG. 3A and portions of triangular profiled sections according to FIG. 13, so that eight girders radially extending can be arranged.
FIGS. 15 and 16 show a sectional view of two embodiments having circular profile of an extruded section according to the invention;
FIG. 17 shows a cross-shaped connecting element;
FIG. 18 shows the assemblage of two girders with circular cross section according to FIG. 15 and a girder according to FIG. 16 connected by connecting elements according to FIG. 17.

DESCRIPTION OF A PREFERRED EMBODIMENT

With reference to FIG. 1, for making a self-supporting framework structure, such as for example the supporting frame 2 of the structure of a pre-fabricated building 1 for use as house, main uprights 3 (FIG. 3A) and main girders 4 and 4a (FIG. 3B or 3C) can be used.
As main upright any of the uprights 3 shown in FIG. 2A with function of pillar is hereinafter indicated, whereas as main girder is hereinafter indicated any of the horizontal girders 4 and 4 a that connect the main uprights to one another.
In FIG. 1 oblique girders 16 are furthermore shown for making the roof, as well as horizontal girders 17 and boards 18 on which the coating of the roof rests. Furthermore supporting boards 20 are shown, connected both to the main uprights that to the main girders.
As shown in FIGS. 3A and 3B, the main uprights 3 and the main girders 4 can be obtained for extrusion, and have the characteristic cross section of a profiled section having outside a plurality of longitudinal grooves 3′ and 4′.
The grooves 3′ and 4′ are alike to each other and have a first undercut portion 24 and a second undercut portion 25. The main girder 4 a of FIG. 3C has an additional profiled wing 28 that protrudes opposite to groove 4′, for locking the supporting boards at the top and the bottom end.
In FIGS. 3D and 3E secondary uprights 14 and 14 a are shown having protruding edges 26 suitable for engaging with the undercut portions 24 of groove 3′ of the main and/or auxiliary upright, for a snap engagement. The secondary upright 14 has the same width as the main girder 4, for the part that protrudes from the groove 3′.
In FIGS. 3F and 3G auxiliary uprights 19 and 19a are shown having T-connections 29 suitable for engaging in undercut portions 25 of grooves 3′ of main uprights 3.
In FIG. 3K, an auxiliary extruded section 19 b is shown suitable for engaging with main upright 3 by means of connecting elements 7 described hereinafter.
In FIG. 3H a secondary girder 15 is shown that has grooves 4′ having the same shape as grooves 3′ and 4′ respectively of the uprights and main girders 3 and 4.
In FIG. 3L an extruded section is shown suitable for being used as main upright 3a for internal partitions, which has rectangular profile and grooves 3′ only on three sides; precisely it has two grooves on a longer side and one groove on two shorter sides.
According to the present invention, it is possible to assemble the pre-fabricated building 1 (FIGS. 1-2B) by fastening uprights 3, 14, 14 a, 19, 19 a, and girders 4, 4 a, 15, obtaining eventually the structure 2, that is light and strong as well as easy and quick to assemble, according to the following steps.
Preferably, a basement 11 (FIG. 2A and 2B) is firstly cast, on which a plurality of plates with fastening elements 12 for main uprights 3 are provided, creating thus the supporting uprights of structure 2. In particular, the fastening elements 12 are protruding towards the above and have cross section equal and complementary to the inner channel 23 of main uprights 3, in which it engages. The grouping is locked with bolts.
With reference to FIGS. 4A and 4B, the uprights are completed by adding to the main uprights 3 the secondary uprights 14,14 a and auxiliary uprights 19, 19 a, or extruded sections 19 b for allowing the fastening of supporting boards 20, both inner and external, and for providing different types of walls, for example as indicated with IV-A and IV-B in FIG. 1. The connections are obtained with snap engagements of the edges 26, or with releasable locking engagement with T-connections 29.
With reference to FIGS. from 5A to 9, for joining to each other girders or uprights that are equipped with the grooves 3′ and 4′, having the relative undercut portions 25, connecting elements 5, 6 a, 6 b, 7, 8, 9 and 10 are used. They are characterised by having each a first rod portion 13 and a second rod portion 13′, having a cross section that matches grooves 3′ and 4′. Each of said rod portions 13 and 13′ has at least a locking block 27 movable between a first position in which it go under the surface of rod 13, 13′ and a second position in which it protrudes from the surface of rod 13, 13′.
The two portions 13 and 13′ sink completely into grooves 3′, 4′.
Typical knots according to the invention for connecting an upright and a girder of the structure 2 are those indicated with X in FIG. 1 and shown in FIGS. 10, 10A and 10B. In this case, for fastening the main girder 4 or 4 a to the main upright 3 the connecting elements 5 (or 6, 7) are used, which have the two rod portions 13 and 13′ orthogonal to each other. By introducing the first portion 13 into said grooves of the main uprights 3, and then manually causing a rotational movement on each of said locking blocks 27, by means of protruding elements with connections for socket head screws 31, it eventually locks the connecting element 5,6 or 7 to main upright 3. In particular, locking block 27 is rotated by means of said socket head screws 31 after reaching the undercut portion 25 of groove 3′. Second portion 13′, which protrudes from grooves 3′, is similarly locked by means of locking blocks 27 in the undercut portions 25 of the grooves 4′ of girders 4 or 4 a. In said position, rod portion 13 cannot exit from the channel 3′ of main upright 3 and rod portion 13′ cannot exit from the channel 4′ of main girder 4 or 4 a. The locking blocks 27 are equipped of auto-locking system of known type, preventing from any undesired rotation.
With reference to FIG. 10C the supporting boards 20 are added. Supporting boards 20 are applied inside and outside the structure 2. They are locked laterally to the main uprights by bayonet sockets (non shown) and contained by the wings 28 of the main girders 4 a, at the top and the bottom end.
Supporting boards 20 have two functions:

- supporting function, as shown in FIG. 10C, since they are connected to the uprights 3 and to the main girders 4 or 4 a, whereby they contribute to bear the action of the weight forces sharing the function of the uprights with the frame of the whole structure;
- shutting function of the apertures of the structure, with creation of a gap between the inner and the external boards, with subsequent possibility of inserting an insulating stuff and installations into the gap.

With reference to FIG. 10D, secondary girders 15 are also added, for completing the structure 2, having the same width of the main uprights 3, and equipped with grooves 4′. By using couples of square connecting elements 8 (FIG. 8), portions 13 engage with the grooves 3′ of uprights 3, whereas portions 13′ engage with the grooves 4′ of secondary girders 15. In a similar way as above described, the locking blocks 27 assure the locking in undercut portions 25 of the respective grooves 3′ and 4′
With reference again to FIG. 1, reference XI, and to FIG. 11, for forming a peaked roof 18, oblique girders are provided 16, having the same cross section of upright 3, or similar. Oblique girders 16 engage with the upper ends of main uprights 3 and traverse 17, having for example cross section the same as secondary girders 15, or similar.
For knot XI of FIG. 1, the connecting elements used, for example 9 and 10 (FIG. 11), have first portion 13 that moves vertically in a respective groove of the upright 3, and second portion 13′ folded at an angle respectively acute or obtuse depending on whether it engages with the descending or ascending portion of the oblique girder 16 with respect to the knot, in a special groove 3′ of the oblique girder 16 same.
Concerning, instead, the two girders 16 at the peak of the roof, according to FIG. 1, particular XII, a connecting element 10 is provided that allows to link them to each other (FIG. 12). In this case, the connecting element 10 has the first portion 13 and second portion 13′ engaging the respective grooves 3′ of said two girders 16.
The same principle for making the roof can be used for making intermediate floors.
The girders and the uprights, in addition to the exemplifying sections, may have even different cross sections, obtained by extrusion of aluminium. For example, the sections used for uprights 3 may have elliptical or rectangular cross section with rounded edges, or triangular profile, or circular profile.
For example, an embodiment according to the invention is shown in FIG. 13 having triangular profile and a groove 3′ arranged on two orthogonal sides 32 and two grooves 3′ on a diagonal side 33. In FIG. 14 an combined upright 35 is shown comprising main uprights 3, according to FIG. 3A, and portions of triangular profiled sections 31 according to FIG. 13, so that eight girders 34 radially extend.
Always for example, as shown in FIGS. 15 and 16 embodiments are also possible with extruded profiled section having circular profile, indicated respectively with 40 and 43. Profiled section 40 has circular profile with inner recess and grooves 3′, like those above described, at opposite sides. The grooves 3′, where not engaged, can be stopped with a closure profiled section 41 or 42. Profiled section 43, of minor cross section, may have at one side a groove 3′ and at the other side a channel 45 for introducing a fastening ridge of a tarpaulin. For connecting two girders 40 to each other, for example forming a vaulted roof, such as a bell or cupola roof, as shown in FIG. 18 cross shaped connecting elements 44 can be used, having locking dogs 27 and two portions 13 and 13′. Such portions, according to the invention, are arranged like a, cross and are suitable for engaging in the respective grooves 3′ at the crossing of two girders 40. To one of the girders 40 a profiled section 43 can then be connected (FIG. 18) for locking a coating tarpaulin not shown, through a channel 45. Obviously, another desired cover can be used.
The foregoing description of a specific embodiment will so fully reveal the invention according to the conceptual point of view, so that others, by applying current knowledge, will be able to modify and/or adapt for various applications such an embodiment without further research and without parting from the invention, and it is therefore to be understood that such adaptations and modifications will have to be considered as equivalent to the specific embodiment. The means and the materials to realise the different functions described herein could have a different nature without, for this reason, departing from the field of the invention. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.

Claims

1-15. (Canceled)

16. A method of providing a self-supporting pre-fabricated framework structure for the building industry, comprising:

pre-arranging a plurality of main uprights (3) as slotted extruded sections having outside a plurality of longitudinal grooves (3′);

introducing connecting elements (5, 6, 7) in said main uprights (3) at predetermined knots, each connecting element (5,6,7) having a first portion (13) that engages and locks into said grooves (3′) and a second portion (13′) that protrudes from said grooves (3′);

connecting to each other said main uprights (3) at said knots using main girders (4) having outside a plurality of longitudinal grooves (4′) in which said second portions (13′) of said connecting elements (5, 6, 7) engage and lock;

wherein at the end of said connection steps, said connecting elements (5, 6, 7) sink in said grooves (3′, 4′).

17. A method according to claim 16, further comprising providing uprights (14, 14 a) and/or secondary girders (15) having same width of said uprights (3) and main girders (4), said secondary uprights (14, 14 a) having the same height as the distance between two consecutive main girders (4) and said secondary girders (15) having the same length as the distance between two consecutive main uprights.

18. The method of claim 17, wherein said secondary uprights and/or girders (14, 14 a) have profiles (26) suitable for snap engaging in the grooves (3′, 4′) of said uprights and main girders (4, 4 a).

19. The method of claim 16, wherein the application is provided of supporting modular external boards (20) to a framework structure formed by the grouping of said uprights (3) and main (4, 4 a) and secondary (14, 14 a, 15) girders, said supporting boards (20) having inside flanged elements that engage with said main uprights (3) along their longitudinal edges and engage with said girders (4) at the top and the bottom end.

20. The method of claim 16, wherein a basement is prearranged comprising a plurality of anchorages for said main uprights (3) which form the supporting uprights of the structure, and then the connection of the main uprights (3) on said anchorages creating said uprights.

21. The method of claim 20, wherein said anchorages are protruding elements (12) protruding from said basement (11) and have cross section equal and complementary to the inner channel of said main uprights (3), the connection being executed introducing said uprights (3) on said protruding elements (12) and locking the matching with locking blocks.

22. The method of claim 17, wherein said or each connecting element (5, 6 a, 6 b) has said portions (13, 13′) formed by at least two orthogonal rods integral to each other, said rods (13,13′) having cross section suitable for engaging in said profiled groove (3′, 4′) of said main uprights and/or girders (4, 4 a), said rods being fixable in the grooves (3′, 4′) of said main girders and uprights (3) by means of quick releasable locking means (27).

23. The method of claim 17, wherein said or each connecting element (7) has said portions (13, 13′) formed by at least two rods parallel and united to each other, said rods (13,13′) having cross section suitable for engaging in said groove (3′) of said uprights (3, 19 b), said rods being fixable in the grooves (3′, 4′) of said main girders and uprights (3) by means of quick releasable locking means (27).

24. The method of claim 16, wherein, for making a roof, oblique girders are provided (16) suitable for engaging with the upper ends of said uprights (3), said connecting elements (9, 10) having said first portion (13) that moves vertically in a respective groove (3′, 4′) of an upright, whereas said second portion (13′) is folded at an angle respectively acute or obtuse depending on whether it engages in the descending or ascending portion of the groove (3′, 4′) of the oblique girder (16) with respect to the knot, connecting elements (10) being provided for connecting two girders (16) at the peak of the roof, having a first and a second portion (13′) engaging the respective grooves (3′, 4′) of said two girders.

25. The method of claim 21, wherein said profiled grooves (3′, 4′) have an opening matching the size of said portions (13,13′), and an undercut inner portion (25) parallel to said opening, each portion of said connecting element comprising at least a locking block (27) movable between a first position in which said locking block goes under each portion (13,13′) and a second position wherein said locking block protrudes from the surface of each portion, in said first position said locking block not blocking the free passage of said portion in the opening of said profiled groove (3′, 4′), in said second position said locking block being suitable for engaging with in said undercut portion inner, whereby said portion is locked in said profiled groove (3′, 4′).

26. A self-supporting pre-fabricated framework structure for the building industry, produced according to the method of claim 16.

27. A self-supporting pre-fabricated framework structure for the building industry, produced according to the method of claim 17.

28. A profiled section to provide a self-supporting pre-fabricated framework structure for the building industry, comprising a profiled section and having a plurality of longitudinal side faces, each side face having at least a groove (3′, 4′) longitudinal with an opening and at least an undercut inner portion (27) parallel to the opening, in said groove (3′, 4′) a first portion (13) engaging of a connecting element having at least another portion (13′) protruding from said groove (3′, 4′), each portion (13, 13′) of said connecting element comprising at least a locking block (27) movable between a first position in which said locking block goes under each portion (13,13′) and a second position in which said locking block protrudes from the surface of each portion (13, 13′), in said first position said locking block not blocking the free passage of said portion (13,13′) in the opening of said groove (3′, 4′), in said second position said locking block being suitable for engaging with said undercut inner portion (25), whereby said first portion (13) is blocked in said groove (3′, 4′), at the end of said connection said connecting elements (5, 6, 7) sinking in said grooves (3′, 4′).

29. A profiled section according to claim 28, wherein surfaces are provided suitable for fastening of boards (20) longitudinally and at the sides of said grooves.

30. A profiled section according to claim 28, said section having a substantially triangular profile (31) with at least one groove (3′) arranged on each side (32, 33).

31. A profiled section according to claim 28, said section having a substantially circular profile (40, 43) with at least a longitudinal groove (3′).