US3712007A - Building system and components therefor - Google Patents

Building system and components therefor Download PDF

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US3712007A
US3712007A US00060520A US3712007DA US3712007A US 3712007 A US3712007 A US 3712007A US 00060520 A US00060520 A US 00060520A US 3712007D A US3712007D A US 3712007DA US 3712007 A US3712007 A US 3712007A
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modules
frames
space
adjacent
frame
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E Kump
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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B1/2403Connection details of the elongated load-supporting parts
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34807Elements integrated in a skeleton
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B1/2403Connection details of the elongated load-supporting parts
    • E04B2001/2415Brackets, gussets, joining plates
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B1/2403Connection details of the elongated load-supporting parts
    • E04B2001/2451Connections between closed section profiles
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B1/2403Connection details of the elongated load-supporting parts
    • E04B2001/2457Beam to beam connections
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B1/2403Connection details of the elongated load-supporting parts
    • E04B2001/2463Connections to foundations

Definitions

  • the structural v A, v mg HWY; frame components comprise column sections having 2,841,832 7/1958 Couse etal .;.....5-2 79 vertical Clusters SUPP members held by hmlmn 2,938,644 5/1960 Cavalier et al. ..220 23 4 ml Web member which also Serves to Support vertical 3,160,244 12 1964 Kushnev etal ..52/221 Service P p and coflduits- Beams Cantilever 3,303,616 2/1967 Brown ..52/221 I war ly from said column sections and are adapted to 3,618,273 11/1971 Crandall...
  • SHEET 10 0F 15 ERNEST J. KUMP BY 31%, W 7L1, mum WW ATTORNEYS I NVE NTOR.
  • PATENTEDJM 23 I975 SHEET llUF 15 INVENTQR. ERNEST J. KUMP WWW ATTORNEYS PATENTEDJAH 23 I975 SHEET lEBF 15 INVENTOR. ERNEST J. KUMP m WATTORNEYS PATENTEDJAH 23 I975 SHEET NW 15 LIIIIIIIIIAL INVENTOR. ERNEST J. KUMP Mada ⁇ 4 4 1! PATENTEDJAN 2 3 197a SHEET lSUF15 L/I/l/VG ROOM STA/RWELL KITCHEN F/G. Z2
  • a modular building structure and components therefor comprising modular supporting frame components whichare assembled to form a plurality of spaced vertical columns with horizontal beams interconnected between said columns at one or more levels; space modules each structurally defining an enclosed volume of space adapted to be supported on said frame, openings formed in each of said walls and a rim at each of said openings to receive a closure for said openings or a connector for connecting the module to an adjacent module, said modules including curved outer walls adapted to accommodate the associated supporting frame; connector and closure means selectively associated with said rims to interconnect selected modules at'selected openings and provide closures for the other openings; and support means adapted to engage selected connector and closure means and serving to support said space modules from said frame at selected locations to form the building structure.
  • FIG. 1 is an elevational view of a portion of a community formed by employing mass produced components in accordance with the present invention.
  • FIG. 2 is a partial sectional view taken along the line 2-2 of FIG. 1 showing a plan view of a portion of the ground floor of the community.
  • FIG. 3 is a sectional view taken along the line 3-3 of FIG. 2 showing an elevation of a portion of the community.
  • FIG. 4 is a sectional view taken along the line 44 of FIG. 1 showing a studio apartment.
  • FIG. 5 is a sectional view taken along the line 5-5 of FIG. 1 showing a two bedroom home.
  • FIG. 6 is :a sectional plan view of a building module in accordance with the invention supported in the frame and connected to associated utilities.
  • FIG. 7 is a sectional elevational view of the module of FIG. 6 showing the module supported on the frame and connected to an adjacent module and to associated utilities.
  • FIG. 8 shows the structural frame components associated with and serving to support the modules.
  • FIG. 9 is a partial sectional view showing the frame and module support cooperating with a module for supporting the same.
  • FIG. 10 is a view taken along the line 10-10 of FIG. 9.
  • FIG. 11 is a sectional view taken along the line 11- 1 l of FIG. 10.
  • FIG. 12 is an enlarged exploded view showing the upper portion of the module support.
  • FIG. 13 is an elevational view showing a single dwelling incorporating components of the present invention.
  • FIG. 14 is a plan view of the building structure shown in FIG. 13.
  • FIG. 15 shows the support for the dwelling of FIGS. 13 and 14.
  • FIG. 16 shows a support for the second floor of the dwelling shown in FIGS. 13 and 14.
  • FIG. 17 is a plan view showing a filler panel for providing patios and outdoor living areas.
  • FIG. 18 is a sectional view taken along the line 18- 18 of FIG. 17.
  • FIGS. 19, and 21 show filler panels associated with the space modules whereby the modules can be employed to form the side walls and ceiling of an enlarged enclosure.
  • FIGS. 22A, B, C and D are sectional plan views of space modules showing various rooms which can be accommodated. 7
  • FIGS. 1, 2 and 3 there is shown a typical community formed of standard mass produced components to be presently described in detail.
  • the community comprises a geometric energized structural frame including spaced vertical cellular columns 11 and horizontal beams 12.
  • the vertical columns 11 include all utilities for the various levels of the community. The utilities are available to adjacent space modules as will be presently described in detail.
  • the columns are supported by suitable foundations 13.
  • the energized space frame supports a plurality of space modules 14 each of which defines an enclosed space.
  • the space modules are suitably supported from the horizontal beams by means of spaced module supports 16.
  • the space module has an exterior curved configuration with openings surrounded by suitable frames which can be interconnected with the frame at adjacent modules as shown generally at 17.
  • the wall openings 18 may be of various sizes to form windows, doorways, etc. They may be relatively wide whereby when two modules are connected to one another, the enclosed space is essentially one room.
  • the modules may include ceiling openings to accommodate skylights or to connect to floor openings of an upper module to form a two-story arrangement.
  • the horizontal beams may also support filler plates 19 which define open spaces, patios, walkways, roadways and parking spaces at various levels and the like between modules. The filler plates also provide fire separation between levels if and when necessary.
  • Stairs 21 may be provided between levels or suitable elevator shafts (not shown) may be supported by the frame to provide access to the various levels.
  • An advantage of a building system in accordance with the invention is that the only element which must be varied regardless of the size or height of the structure is the load capacity of the vertical columns which is achieved by controlling the thickness of the vertical components. All the physical and structural characteristics of the other components and subcomponents of the system remain identical regardless of the height or complexity of the building system.
  • the exterior curved profile of the space modules provides the necessary space surrounding the modules to accommodate the vertical and horizontal components of the space frame. It also provides air space about the modules. The curvature of the modules also increases the structural efficiency of the module walls in comparison to square or rectangular modules. The space created around all interconnecting space modules also minimizes sound transmission between adjacent modules. The space provides access to outside air for ventilation and air-conditioning of each space module irrespectively of where it is located in the multilateral organization of the space modules.
  • areas between vertical columns may be left open, such as shown at 23 and 24, to provide streets.
  • the space modules themselves may be used to form walls of enclosures such as auditoriums, stores, classrooms, theatres and the like.
  • An enclosed space is shown at 26.
  • the plurality of interconnected space modules 27 form the side walls.
  • the modules may be used as large blocks in defining the walls of the enclosure 26.
  • the enclosure may, of course, be subdivided to form a plurality of rooms.
  • the individual modules forming the side walls can be used as offices, storage rooms, lavatories, etc.
  • the enclosures may have a height corresponding to the height of one or more modules such as shown in FIG.
  • the upper modules may be interconnected to form multi-purpose rooms, offices and the like.
  • suitable side and top closure panels are provided to fit between and seal with the exterior walls-of the space module.
  • FIG. 4 is a sectional view taken at the line 4-4 of FIG. 1 and shows a two-room studio apartmentwhich includes a bedroom 25, kitchenette 29 and an outdoor patio 30 which leads to the stairway 21.
  • FIG. 5 shows a dwelling unit comprising a living room 31, a kitchen 32, bathroom 33 and bedrooms 34. It will, of course, be apparent that one can select any number of modules and interconnect the same to form living space with any desired room arrangement and room size.
  • the space module 14 is shown in more detail in FIGS. 6, 7, 9, 22A, 22B, 22C and 22D.
  • the space module is a hollow cube-shaped enclosure having rounded outer walls-
  • the walls may be constructed of expanded material, such as polyethylene or polyurethane with a fiberglass interior and exterior skin.
  • the composite assembly has structural strength and also provides thermal and sound insulation.
  • the openings 41 are provided with a hollow frame 42 which may be metal, plastic or other suitable material.
  • the frame may include an extruded element 43 and cover 44.
  • the space 45 defined by the extruded element 43 and cover 44 serves as a raceway for electrical wiring with the cover 44 accommodating electrical fixtures such as plugs and switches.
  • the space 45 is connected to floor raceways 46 which are in the form of a cross which interconnects the four frames 41. Electrical power may be applied to the frames and floor raceway by means of a conduit 47, FIG. 6, carried by the adjacent column.
  • the extruded frame also includes an exterior projecting rim portion 48 which accepts a collar connector component, hereinafter described in detail.
  • the connector serves to interconnect and seal one module to an adjacent module and to provide simultaneously a door stop and module support.
  • the rim may also accept closure components such as doors and windows and mechanical components such as fans and air-conditioning units, or a fireplace unit.
  • the building module may be radiantly heated by means of oils 49 embedded in the wall and floor of the structure or may be heated by floor heaters or baseboard heaters (not shown) energized by the electrical system at the frame.
  • Air-conditioning (not shown) for each of the modules may be provided by an air-conditioner which fits into one of the openings 41 and is supported by the frame.
  • a vent and soil pipe may be formed in the wall of the module on opposite corners thereof.
  • the vent and soil pipe may be connected to the associated soil line, accommodated in the vertical columns as will be presently described.
  • a soil pipe is schematically illustrated at 51, FIG. 6, connected to the common soil line 52 in the vertical column.
  • the soil pipe illustrated is a concentric soil pipe with the central pipe forming the soil pipe and the annular space between pipes, the vent.
  • Fire protection may be provided in each module by integrally building into the floor or wall of the module means for accommodating a carbon dioxide supply such as shown at 53, FIG. 6.
  • the directed nozzle 54 is adapted to spray the interior of the module with carbon dioxide to extinguish a fire.
  • each modular building space is self-contained including suitable electrical raceways surrounding each of the exterior openings and serving not only to define the opening, but also to receive electrical components and adapted to be interconnected with frames of adjacent panels to form multiple module buildings and also serving to support the space module.
  • the space modules may be formed by use of a honeycomb core with spaced skins or molded thin shell concrete, or may use more conventional methods of construction, such as framing members with attached outer and inner walls.
  • the exterior finishes may have any color, texture and finish to provide an aesthetic and differing appearance throughout the space structure.
  • the structural frame comprising the energized cellular vertical columns 11 and the horizontal beams 12 is shown in more detail in FIGS. 6, 7, 8, 9 and 10.
  • the columns 11 comprise a cluster of four vertical structural tubes 56 which are held and maintained in spaced relationship by spaced plates 57.
  • the members 56 form the supporting columns of the cellular cluster and are sized to accommodate the weight of the building and the lateral forces.
  • the plates 57 may be used to support a cluster of pipes and conduits which energize the space frame.
  • the central opening serves to support the soil pipe 52 which may be a double pipe with the inner pipe serving to carry the soil while the outer concentric pipe provides the vent.
  • the outer portions of the web serve to support vertical electrical conduits 58, pipes 59, TV cables 61, telephone cables and the like.
  • the utility pipes and conduits may be supported in the cellular column in other ways such as by hangers extending from the column tubes.
  • each of the vertical cellular columns is self-energized and adapted to be adjacent a space module supported on the structure. Consequently, the modules can be easily connected to receive the desired utilities.
  • the horizontal beams 12 are preferably attached to the vertical members 56 as, for example, by welding to cantilever outwardly from the column to span from one column to the next, or to a connector.
  • the beams 12 define a supporting grid adapted to support four modules between four spaced columns whereby one corner of each of the four modules is adjacent a column.
  • the beams and columns are formed at the factory as a component assembly which includes a section of column 62 adapted to be joined to other sections to form the vertical column 11.
  • the section of column 62 has a length equal to the distance between levels of the multi-story structure.
  • the upper ends of the members 56 and the pipes and conduits are adapted to interconnect to the lower ends of adjacent pipes and conduits to provide a continuous vertical column.
  • each of the column sections will include four cantilevered branches 12a, 12b, 12c and 12d forming a portion of the support beam 12 and extending generally from the mid-point of the column section 62.
  • a modular cross beam 63 interconnects the ends of the branches of adjacent column modules or other cross beams.
  • the modular cross beam comprises beam portions 64a, 64b, 64c and 64d secured to one another to form a cross with the ends of the cross adapted to be joined to adjacent ends of the branches of the column support.
  • the central portion of a cross beam structure is reinforced with a plate 63.
  • the action of the cantilevered branch beams, associated column sections and cross beams is to form a threehinged arch support making it possible to erect the framework without the necessity of staging.
  • the outer cantilevered branches may support space modules which cantilever out from the structure.
  • each of the modules is supported by a member 16.
  • the member 16 serves the purpose of supporting the space modules on the horizontal beams leveling the space module and joining adjacent beam members.
  • a typical beam connector and support is shown in FIGS. 7 through 11.
  • the beam connector includes an adaptor 66 which slides into the ends of adjoining box beams 12, for example, beams 12a and 64a, FIG. 11.
  • the connector is joined to the beam by means of bolts 67 or other suitable means whereby to hold together the horizontal beam sections.
  • the upper portions of the beams 12 and 64 are provided with cutouts whereby an opening 68 is formed in the upper portion to accommodate the base 69 of the screw portion 71.
  • the base 69 is secured to the adaptor 66.
  • the lower portion of the jack includes a portion 72 adapted to receive a wrench or other suitable tool for rotating the jack screw to raise and lower the associated support 73.
  • the support 73 extends upwardly and receives cradle 74 of a module connector. Thus, by rotating the screw 71, the position of the support 73 may be lowered and raised to level an associated module.
  • the cradle 74 includes a support plate 77 secured between cradle 74 and support 73 to provide a rigid support for the cradle ends.
  • the cradle 74 includes a pair of V-shaped projections 78 and 79, each adapted to engage an associated groove formed in the rim of a pair of adjoining modules or a groove in the rim of a module and a groove in an associated closure such as for doors, windows or the like.
  • Four such connectors and supports are associated with each module and are adapted to support the module from the beams at four points and provide means for leveling the same. Where the module is cantilevered from branches, less than four supports are used.
  • the door frame in each of the modules is a raceway formed by an extruded member and including a collar rim 48 which includes a groove adapted to receive a V-shaped projection.
  • the cradle support will engage the grooves in each of the facing modules.
  • a collar connector engages the sides and top of the rim.
  • Such collar connector preferably comprises a U-shaped member which is adapted to extend over the top of the opening and which includes V- shaped projections 79 and 80, FIG. 12, and a central plate member 82 which fits into the slot 83 formed in the cradle and cradle support.
  • the member 82 fits between the faces of the cooperating module collars and also extends inwardly a short distance as shown at 84, FIG. 16, to form a door stop.
  • the collar connector and support cradle and member 16 are held in assembled relationship by bolt 86. Screws 85 (FIG. 9) engage the plate and rims from inside the module to draw the modules or modules and closures together.
  • the module collar member is also adapted to receive window and door frames.
  • the outer portion of the collar is extruded to form a pair of guides 87 and 88 which receive sliding doors 89 and 90, respectively.
  • the frame member may be extruded to receive windows, air-conditioning, fireplaces or other mechanical equipment and support the same from the module frame.
  • the collar receives a closure for the module and cooperates with a support, as described above, to hold the space module.
  • a sealing gasket 92 is provided between the frame rim grooves and the connecting collar to form a tight seal between modules or between modules and closure members.
  • the adjustable support may rest on the horizontal beams rather than be part of a connector.
  • the collar may be clamped to the rim rather than slide over and engage the rim.
  • Other connecting and support means can be designed to persons skilled in the art.
  • the preferred described support and connecting collar offer many advantages.
  • FIGS. 13 and 14 Typical single dwellings are shown in FIGS. 13 and 14 and comprise a two-story structure composed of six modules 14.
  • the lower modules are supported from the ground by means of support 16 secured to piers 17.
  • the upper modules are supported by support 16a supported from the rim and collar of the lower module. Access between modules at various levels may be provided by a circular staircase extending through ceiling and floor openings indicated schematically at 93. Decks and the like are also shown.
  • the pier 17 is adapted to receive a plate 94 which has a member 96 for receiving the lower base 69 of the screw 71 provided with activating nut 72.
  • the extension 73 extends upwardly and is adapted to hold the cradle 74.
  • the connector collar plate fits in the slot and is secured to the cradle.
  • the second level is supported by an extension 97 which is adapted to fit upon the top of the collar connection of the lower module and which extends upwardly and serves to receive the base 69 with the remaining portions of the jack bearing reference numerals like those previously described and extending upwardly to hold the cradle 74 for the upper collar connector.
  • Such a filler panel may be a square member such as shown in FIGS. 17 and 18.
  • the member may be concrete with a plurality of intersecting ribs 98 providing reinforcement for the flat slab 99.
  • the panel rests on the edges of the beams.
  • the panel includes cutouts 101 for accommodating the supports and cutouts 102 adapted to accommodate the plate connectors 57 associated with the columns.
  • the space may also be filled by a wood deck or the like.

Abstract

A building system employing standardized mass produced components cable of being assembled to form a large variety of different building structures, from simple individual dwellings to complex communities, by the selection of different combinations of standard components. The standard components include structural frame components, space modules and supports which support the space modules from the assembled frame components. The structural frame components comprise column sections having vertical clusters of support members held by horizontal web member which also serves to support vertical service pipes and conduits. Beams cantilever outwardly from said column sections and are adapted to be connected to beams of adjacent column sections, or to a cross beam which connects between adjacent column sections. The connection can be by means of a connector which also forms the support for the modules. The space each structurally define a volume of space with openings including frame means which are engaged by connecting collars to join adjacent modules and to engage with connectors to support the modules. Closure components are interchangeable with the frame means to form doors and windows.

Description

Umted States Patent 1 1 1111 3,712,007 Kump 1 1 Jan. 23, 1973 54 -BU1L1)1N Y T AND "3,566,553" 3/1971 Schaffer ..52/79 COMPONENTS THEREFOR FCREIGN PATENTS OR APPLICATIONS [76] Inventor: Ernest Joseph Kump, 360 Everett --r 1 Avenue, p Alto, Calif. 94301 1,577,362 [969 France ...52/l26 7 i 1 Filed: 3, 1970 f Primary Examiner-Henry C. Sutherland [2H APPL NOJ 60,520 Attorney-Flehr, Hohbach, Test, Albritton & Herbert I [57] ABSTRACT [52] US. Cl. ..52/79, 52/23 6, 52/648 51 1m. (:1 ..E04h 1/12, E04h 9/06 A buldmg system emphymg .andmdmd mass [58] Field of Search ..52/79 236 126 125 234' p-mducedi l 52/122 221 4 form a large varlety of d1fferent bulldmg structures, front'simple individual dwellings to complex commun ities, by the selection of .different combinations of WM standard components. The standard components in- [56] References Cited clude structural frame components, space modules and supports which support the space modules from UNITED STATES PATENTS the assembled frame components. The structural v A, v mg HWY; frame components comprise column sections having 2,841,832 7/1958 Couse etal .;.....5-2 79 vertical Clusters SUPP members held by hmlmn 2,938,644 5/1960 Cavalier et al. ..220 23 4 ml Web member which also Serves to Support vertical 3,160,244 12 1964 Kushnev etal ..52/221 Service P p and coflduits- Beams Cantilever 3,303,616 2/1967 Brown ..52/221 I war ly from said column sections and are adapted to 3,618,273 11/1971 Crandall... .....52/236 5 be connected to beams of adjacent column sections, 3,564,786 2/1971 Baker 52/79 or to a cross beam which connects between adjacent 3,363,370 Comoletti column Sections The connection can be means of a 333L170 7/l967 E connector which also forms the support for the 2'499'498 1 3/1950 Hammwd modules. The space each structurally define a volume $232222 of space with openings including frame means which 6/1970 Comm are engaged by connecting collars to join adjacent 527,002 9/1970 Mead ..52/83 "wdules and to engage will cmmecm m modules. Closure components are interchangeable with the frame means to form doors and windows.
16 Claims, 26 Drawing Figures PATENTEBJAH23 I975 3,712,007
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PATENTEDJM 23 I975 SHEET llUF 15 INVENTQR. ERNEST J. KUMP WWW ATTORNEYS PATENTEDJAH 23 I975 SHEET lEBF 15 INVENTOR. ERNEST J. KUMP m WATTORNEYS PATENTEDJAH 23 I975 SHEET NW 15 LIIIIIIIIIIIIAL INVENTOR. ERNEST J. KUMP Mada} 4 4 1! PATENTEDJAN 2 3 197a SHEET lSUF15 L/I/l/VG ROOM STA/RWELL KITCHEN F/G. Z2
INVENTOR. ERNEST J. KUMP ATTOHNFYS BUILDING SYSTEM AND COMPONENTS THEREFOR BACKGROUND OF THE INVENTION This invention relates generally to a building system employing standardized mass produced building components to form a large variety of different building structures.
Today, no method for producing housing, whether under cover using processes that resemble but are not actually true assembly line production.
These archaic approaches are primarily the result of the reluctance of trying to mechanize traditional building techniques and to preserve so-called traditional house appearance. Basically, the prior art techniques and concept produce houses with relatively fixed plans. They are limited to one-story or low rise horizontal arrangements which result in mass monotony and waste of land without appreciably reducing costs.
At present there is no industrialized housing system that can be economically factory produced in annual quantities such as are achieved by the automobile industry, nor does such a system appear to have as yet been conceived. There is no housing system in which the finished components are produced in factories throughout the United States and yet which provide the same comfort and convenience as any other house regardless of price. That is a system employing mass produced components in which the resultant structure fulfills all basic necessities of housing including air-conditioning, heating, plumbing, laundry, television and the like. In short, everything that one needs for physical and human creature comfort that is available on the market of this highly industrialized nation is not presently available in housing on an industrialized ba- SIS.
Furthermore, there is no modular building system in which the components can be assembled to form communities including auditoriums, stores, theatres and other community structures.
OBJECTS AND SUMMARY OF THE INVENTION It is a general object of the present invention to provide an improved modular building system.
It is another object of the present invention to provide a building system which is adapted to industrialized mass production techniques.
It is a further object of the present invention to provide a self-contained space module which can be supplied in quantity and which interrelates with other modules to form every building type, i.e. dwellings, villages, schools, hotels, stores, communities, and other building structures. I
It is a further object of the present invention to provide a modular space frame adapted to receive modules and support them and which incorporates service utility lines for connection to modules supported on the space frame.
It is a further object of the present invention to provide a building system which preserves the natural ecology, drainage and topography of the building site and which can utilize land which would not otherwise be useful for either buildings or for agricultural uses.
A modular building structure and components therefor comprising modular supporting frame components whichare assembled to form a plurality of spaced vertical columns with horizontal beams interconnected between said columns at one or more levels; space modules each structurally defining an enclosed volume of space adapted to be supported on said frame, openings formed in each of said walls and a rim at each of said openings to receive a closure for said openings or a connector for connecting the module to an adjacent module, said modules including curved outer walls adapted to accommodate the associated supporting frame; connector and closure means selectively associated with said rims to interconnect selected modules at'selected openings and provide closures for the other openings; and support means adapted to engage selected connector and closure means and serving to support said space modules from said frame at selected locations to form the building structure.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an elevational view of a portion of a community formed by employing mass produced components in accordance with the present invention.
FIG. 2 is a partial sectional view taken along the line 2-2 of FIG. 1 showing a plan view of a portion of the ground floor of the community.
FIG. 3 is a sectional view taken along the line 3-3 of FIG. 2 showing an elevation of a portion of the community.
FIG. 4 is a sectional view taken along the line 44 of FIG. 1 showing a studio apartment.
FIG. 5 is a sectional view taken along the line 5-5 of FIG. 1 showing a two bedroom home.
FIG. 6 is :a sectional plan view of a building module in accordance with the invention supported in the frame and connected to associated utilities.
FIG. 7 is a sectional elevational view of the module of FIG. 6 showing the module supported on the frame and connected to an adjacent module and to associated utilities.
FIG. 8 shows the structural frame components associated with and serving to support the modules.
FIG. 9 is a partial sectional view showing the frame and module support cooperating with a module for supporting the same.
FIG. 10 is a view taken along the line 10-10 of FIG. 9.
FIG. 11 is a sectional view taken along the line 11- 1 l of FIG. 10.
FIG. 12 is an enlarged exploded view showing the upper portion of the module support.
FIG. 13 is an elevational view showing a single dwelling incorporating components of the present invention.
FIG. 14 is a plan view of the building structure shown in FIG. 13.
FIG. 15 shows the support for the dwelling of FIGS. 13 and 14.
FIG. 16 shows a support for the second floor of the dwelling shown in FIGS. 13 and 14.
FIG. 17 is a plan view showing a filler panel for providing patios and outdoor living areas.
FIG. 18 is a sectional view taken along the line 18- 18 of FIG. 17.
FIGS. 19, and 21 show filler panels associated with the space modules whereby the modules can be employed to form the side walls and ceiling of an enlarged enclosure.
FIGS. 22A, B, C and D are sectional plan views of space modules showing various rooms which can be accommodated. 7
DESCRIPTION OF THE PREFERRED EMBODIMENT Building System In FIGS. 1, 2 and 3 there is shown a typical community formed of standard mass produced components to be presently described in detail. The community comprises a geometric energized structural frame including spaced vertical cellular columns 11 and horizontal beams 12. The vertical columns 11 include all utilities for the various levels of the community. The utilities are available to adjacent space modules as will be presently described in detail. The columns are supported by suitable foundations 13.
The energized space frame supports a plurality of space modules 14 each of which defines an enclosed space. The space modules are suitably supported from the horizontal beams by means of spaced module supports 16. The space module has an exterior curved configuration with openings surrounded by suitable frames which can be interconnected with the frame at adjacent modules as shown generally at 17. The wall openings 18 may be of various sizes to form windows, doorways, etc. They may be relatively wide whereby when two modules are connected to one another, the enclosed space is essentially one room. In certain instances the modules may include ceiling openings to accommodate skylights or to connect to floor openings of an upper module to form a two-story arrangement. The horizontal beams may also support filler plates 19 which define open spaces, patios, walkways, roadways and parking spaces at various levels and the like between modules. The filler plates also provide fire separation between levels if and when necessary. Stairs 21 may be provided between levels or suitable elevator shafts (not shown) may be supported by the frame to provide access to the various levels.
An advantage of a building system in accordance with the invention is that the only element which must be varied regardless of the size or height of the structure is the load capacity of the vertical columns which is achieved by controlling the thickness of the vertical components. All the physical and structural characteristics of the other components and subcomponents of the system remain identical regardless of the height or complexity of the building system.
The exterior curved profile of the space modules provides the necessary space surrounding the modules to accommodate the vertical and horizontal components of the space frame. It also provides air space about the modules. The curvature of the modules also increases the structural efficiency of the module walls in comparison to square or rectangular modules. The space created around all interconnecting space modules also minimizes sound transmission between adjacent modules. The space provides access to outside air for ventilation and air-conditioning of each space module irrespectively of where it is located in the multilateral organization of the space modules.
It is further noted that the significant ecological advantages are achieved in the building system in ac-" cordance with the invention. This results from the fact that the column supports 11 for the entire space frame regardless of its magnitude and extent are supported by spaced concrete piles 13. These require only a series of simple circular penetrations into the soil eliminating the necessity and brutality of expensive mass grading, cut and fill the other traditional means of site preparation which destroys the natural ecology, drainage and topography of the site. The simplicity of the foundation and character of the space frame also makes it possible to create a building structure on a sloping or rugged site or on swamps or the like as easily as upon a level site. This eliminates the necessity, for economic reasons, of using major areas of valuable agricultural land for housing and community development projects.
Referring again to FIGS. 1, 2 and 3, it is seen that areas between vertical columns may be left open, such as shown at 23 and 24, to provide streets. Furthermore, the space modules themselves may be used to form walls of enclosures such as auditoriums, stores, classrooms, theatres and the like. An enclosed space is shown at 26. The plurality of interconnected space modules 27 form the side walls. The modules may be used as large blocks in defining the walls of the enclosure 26. The enclosure may, of course, be subdivided to form a plurality of rooms. The individual modules forming the side walls can be used as offices, storage rooms, lavatories, etc. The enclosures may have a height corresponding to the height of one or more modules such as shown in FIG. 3 wherein the two tiers of modules 27a and 27b form the side wall, while the third tier of modules 28 is continuous to form the roof or ceiling for the enclosure. The upper modules may be interconnected to form multi-purpose rooms, offices and the like. To seal or enclose the building space 26, suitable side and top closure panels are provided to fit between and seal with the exterior walls-of the space module.
The community, of course, includes individual dwellings at the various levels. The dwellings may comprise one or more space modules interconnected to form the living space. By way of example, FIG. 4 is a sectional view taken at the line 4-4 of FIG. 1 and shows a two-room studio apartmentwhich includes a bedroom 25, kitchenette 29 and an outdoor patio 30 which leads to the stairway 21. FIG. 5 shows a dwelling unit comprising a living room 31, a kitchen 32, bathroom 33 and bedrooms 34. It will, of course, be apparent that one can select any number of modules and interconnect the same to form living space with any desired room arrangement and room size.
Space Module The space module 14, FIGS. 1, 2 and 3, is shown in more detail in FIGS. 6, 7, 9, 22A, 22B, 22C and 22D. The space module is a hollow cube-shaped enclosure having rounded outer walls- The walls may be constructed of expanded material, such as polyethylene or polyurethane with a fiberglass interior and exterior skin. The composite assembly has structural strength and also provides thermal and sound insulation. Preferably, the openings 41 are provided with a hollow frame 42 which may be metal, plastic or other suitable material. The frame may include an extruded element 43 and cover 44. The space 45 defined by the extruded element 43 and cover 44 serves as a raceway for electrical wiring with the cover 44 accommodating electrical fixtures such as plugs and switches. The space 45 is connected to floor raceways 46 which are in the form of a cross which interconnects the four frames 41. Electrical power may be applied to the frames and floor raceway by means of a conduit 47, FIG. 6, carried by the adjacent column. The extruded frame also includes an exterior projecting rim portion 48 which accepts a collar connector component, hereinafter described in detail. The connector serves to interconnect and seal one module to an adjacent module and to provide simultaneously a door stop and module support. The rim may also accept closure components such as doors and windows and mechanical components such as fans and air-conditioning units, or a fireplace unit.
The building module may be radiantly heated by means of oils 49 embedded in the wall and floor of the structure or may be heated by floor heaters or baseboard heaters (not shown) energized by the electrical system at the frame. Air-conditioning (not shown) for each of the modules may be provided by an air-conditioner which fits into one of the openings 41 and is supported by the frame.
A vent and soil pipe may be formed in the wall of the module on opposite corners thereof. The vent and soil pipe may be connected to the associated soil line, accommodated in the vertical columns as will be presently described. A soil pipe is schematically illustrated at 51, FIG. 6, connected to the common soil line 52 in the vertical column. The soil pipe illustrated is a concentric soil pipe with the central pipe forming the soil pipe and the annular space between pipes, the vent.
Fire protection may be provided in each module by integrally building into the floor or wall of the module means for accommodating a carbon dioxide supply such as shown at 53, FIG. 6. The directed nozzle 54 is adapted to spray the interior of the module with carbon dioxide to extinguish a fire.
Thus, it is seen that each modular building space is self-contained including suitable electrical raceways surrounding each of the exterior openings and serving not only to define the opening, but also to receive electrical components and adapted to be interconnected with frames of adjacent panels to form multiple module buildings and also serving to support the space module.
It is, of course, apparent that the space modules may be formed by use of a honeycomb core with spaced skins or molded thin shell concrete, or may use more conventional methods of construction, such as framing members with attached outer and inner walls. The exterior finishes may have any color, texture and finish to provide an aesthetic and differing appearance throughout the space structure.
Structural Frame The structural frame comprising the energized cellular vertical columns 11 and the horizontal beams 12 is shown in more detail in FIGS. 6, 7, 8, 9 and 10. The columns 11 comprise a cluster of four vertical structural tubes 56 which are held and maintained in spaced relationship by spaced plates 57. The members 56 form the supporting columns of the cellular cluster and are sized to accommodate the weight of the building and the lateral forces. Thus, in multiple story buildings the lower members 56-are designed with thicker walls to support more weight and withstand more lateral forces than the upper members.
The plates 57 may be used to support a cluster of pipes and conduits which energize the space frame. For example, the central opening serves to support the soil pipe 52 which may be a double pipe with the inner pipe serving to carry the soil while the outer concentric pipe provides the vent. The outer portions of the web serve to support vertical electrical conduits 58, pipes 59, TV cables 61, telephone cables and the like. It is, of course, apparent that the utility pipes and conduits may be supported in the cellular column in other ways such as by hangers extending from the column tubes. Thus, each of the vertical cellular columns is self-energized and adapted to be adjacent a space module supported on the structure. Consequently, the modules can be easily connected to receive the desired utilities.
The horizontal beams 12 are preferably attached to the vertical members 56 as, for example, by welding to cantilever outwardly from the column to span from one column to the next, or to a connector. The beams 12 define a supporting grid adapted to support four modules between four spaced columns whereby one corner of each of the four modules is adjacent a column.
In accordance with another feature of the invention, the beams and columns are formed at the factory as a component assembly which includes a section of column 62 adapted to be joined to other sections to form the vertical column 11. Preferably, the section of column 62 has a length equal to the distance between levels of the multi-story structure. The upper ends of the members 56 and the pipes and conduits are adapted to interconnect to the lower ends of adjacent pipes and conduits to provide a continuous vertical column. In addition, each of the column sections will include four cantilevered branches 12a, 12b, 12c and 12d forming a portion of the support beam 12 and extending generally from the mid-point of the column section 62.
A modular cross beam 63 interconnects the ends of the branches of adjacent column modules or other cross beams. The modular cross beam comprises beam portions 64a, 64b, 64c and 64d secured to one another to form a cross with the ends of the cross adapted to be joined to adjacent ends of the branches of the column support. Referring to FIG. 8, the central portion of a cross beam structure is reinforced with a plate 63. The action of the cantilevered branch beams, associated column sections and cross beams is to form a threehinged arch support making it possible to erect the framework without the necessity of staging. The outer cantilevered branches may support space modules which cantilever out from the structure.
Collar Connector and Support As previously described with reference to FIGS. 1, 2 and 3, each of the modules is supported by a member 16. The member 16 serves the purpose of supporting the space modules on the horizontal beams leveling the space module and joining adjacent beam members. A typical beam connector and support is shown in FIGS. 7 through 11. The beam connector includes an adaptor 66 which slides into the ends of adjoining box beams 12, for example, beams 12a and 64a, FIG. 11. The connector is joined to the beam by means of bolts 67 or other suitable means whereby to hold together the horizontal beam sections. The upper portions of the beams 12 and 64 are provided with cutouts whereby an opening 68 is formed in the upper portion to accommodate the base 69 of the screw portion 71. The base 69 is secured to the adaptor 66. The lower portion of the jack includes a portion 72 adapted to receive a wrench or other suitable tool for rotating the jack screw to raise and lower the associated support 73. The support 73 extends upwardly and receives cradle 74 of a module connector. Thus, by rotating the screw 71, the position of the support 73 may be lowered and raised to level an associated module. The cradle 74 includes a support plate 77 secured between cradle 74 and support 73 to provide a rigid support for the cradle ends. The cradle 74 includes a pair of V-shaped projections 78 and 79, each adapted to engage an associated groove formed in the rim of a pair of adjoining modules or a groove in the rim of a module and a groove in an associated closure such as for doors, windows or the like. Four such connectors and supports are associated with each module and are adapted to support the module from the beams at four points and provide means for leveling the same. Where the module is cantilevered from branches, less than four supports are used.
As previously described, the door frame in each of the modules is a raceway formed by an extruded member and including a collar rim 48 which includes a groove adapted to receive a V-shaped projection. When modules are placed adjacent to one another for connection, the cradle support will engage the grooves in each of the facing modules.
In addition, a collar connector engages the sides and top of the rim. Such collar connector preferably comprises a U-shaped member which is adapted to extend over the top of the opening and which includes V- shaped projections 79 and 80, FIG. 12, and a central plate member 82 which fits into the slot 83 formed in the cradle and cradle support. The member 82 fits between the faces of the cooperating module collars and also extends inwardly a short distance as shown at 84, FIG. 16, to form a door stop. The collar connector and support cradle and member 16 are held in assembled relationship by bolt 86. Screws 85 (FIG. 9) engage the plate and rims from inside the module to draw the modules or modules and closures together.
The module collar member is also adapted to receive window and door frames. Referring to FIG. 9, the outer portion of the collar is extruded to form a pair of guides 87 and 88 which receive sliding doors 89 and 90, respectively. It is, of course, apparent that rather than sliding doors, the frame member may be extruded to receive windows, air-conditioning, fireplaces or other mechanical equipment and support the same from the module frame. Thus, the collar receives a closure for the module and cooperates with a support, as described above, to hold the space module. A sealing gasket 92is provided between the frame rim grooves and the connecting collar to form a tight seal between modules or between modules and closure members.
Although a preferred support and connecting collar has been described, it is apparent that other designs may be employed to support and connect the modules and closures. For example, the adjustable support may rest on the horizontal beams rather than be part of a connector. The collar may be clamped to the rim rather than slide over and engage the rim. Other connecting and support means can be designed to persons skilled in the art. However, the preferred described support and connecting collar offer many advantages.
Single Dwelling In certain instances it may be desirable to form housing employing a space module of the type described. Typical single dwellings are shown in FIGS. 13 and 14 and comprise a two-story structure composed of six modules 14. The lower modules are supported from the ground by means of support 16 secured to piers 17. The upper modules are supported by support 16a supported from the rim and collar of the lower module. Access between modules at various levels may be provided by a circular staircase extending through ceiling and floor openings indicated schematically at 93. Decks and the like are also shown.
Referring specifically to FIGS. 15 and 16, the support for a two-story building of the type described is shown. The pier 17 is adapted to receive a plate 94 which has a member 96 for receiving the lower base 69 of the screw 71 provided with activating nut 72. The extension 73 extends upwardly and is adapted to hold the cradle 74. The connector collar plate fits in the slot and is secured to the cradle.
The second level is supported by an extension 97 which is adapted to fit upon the top of the collar connection of the lower module and which extends upwardly and serves to receive the base 69 with the remaining portions of the jack bearing reference numerals like those previously described and extending upwardly to hold the cradle 74 for the upper collar connector.
It is seen that the collar connectors, modules and other elements are identical to those' previously described and the only difference is that in a single dwelling structure the requirement for vertical columns is eliminated.
Filler Panels There were previously described filler panels serving to cover open portions of the supporting beam grid. Such a filler panel may be a square member such as shown in FIGS. 17 and 18. The member may be concrete with a plurality of intersecting ribs 98 providing reinforcement for the flat slab 99. The panel rests on the edges of the beams. The panel includes cutouts 101 for accommodating the supports and cutouts 102 adapted to accommodate the plate connectors 57 associated with the columns. The space may also be filled by a wood deck or the like.

Claims (16)

1. A modular building structure comprising a plurality of cube shaped space modules each having four outer walls structurally defining a volume of space, an opening formed in each wall of said modules, a frame inside surrounding each of said openings and extending beyond said outer walls, said modules being placed adjacent to one another with selected frames of adjacent modules being disposed in face to face relation to provide direct communication between modules, a collar engaging said selected face to face frames to directly interconnect adjacent modules at said adjacent selected frames, closure means for closing the openings defined by the other frames of each of said modules, supports, and support means having one end in engagement with said collar and the other end with said supports for supporting the modules solely by said frames at said openings.
2. A modular building structure as in claim 1 wherein said support means are adjustable to level the associated modules.
3. A modular building structure as in claim 2 wherein said support comprises a foundation member.
4. A modular building structure as in claim 2 wherein modules are placed above one another and the support means for the upper modules rests on the frames of the next adjacent lower module.
5. A modular building structure comprising a supporting structure including a plurality of spaced vertical columns and horizontal beams interconnected between said columns at one or more levels to form a rigid support system; space modules each structurally defining an enclosed space adapted to be supported on said frame, openings formed in each of said modules, a frame surrounding each of said openings, said modules being placed adjacent to one another with selected frames of adjacent modules being disposed in face to face relation to provide direct communication between modules, means connecting said face to face frames thereby directly interconnecting adjacent modules at said frames, means closing the openings defined by the other frames of said modules, said modules including curved outer surfaces adapted to accommodate the associated supporting frame and to provide air circulation and sound isolation between adjaceNt modules; and support means adapted to engage said frames and said structure and support said space modules solely from said frame.
6. A modular building structure as in claim 1 wherein said frame includes an outwardly extending portion at each of said openings whereby to receive the interconnect means and maintain the adjacent modules spaced from one another to provide air circulation and sound isolation between adjacent modules.
7. A modular building structure comprising a supporting structure including a plurality of spaced vertical columns and horizontal beams interconnected between said columns at one or more levels; space modules each structurally defining an enclosed space, openings formed in each of said modules, a frame surrounding each of said openings, said modules being placed adjacent to one another with selected frames of adjacent modules being disposed in face to face relation to provide direct communication between modules, connecting means engaging said frames to directly interconnect said adjacent modules at said frames, means closing the openings defined by the other frames, said modules including curved outer surfaces adapted to accommodate the associated supporting frame; and support means disposed to engage said frames and said horizontal beams to support said space modules from said supporting structure solely at said frames.
8. A modular building structure as in claim 7 wherein said supporting means are adjustable to level the associated space module.
9. A modular building structure as in claim 7 wherein said frame includes a rim.
10. A modular building structure as in claim 9 wherein said frame includes raceways for accommodating utilities and said modules include raceways communicating between the frame raceways.
11. A modular building structure as in claim 7 wherein said connecting means and means for closing includes a collar member adapted to surround at least a portion of said opening and engage the frames of adjacent modules to secure the modules to each other, said collar also including means for engaging said support means for supporting the module.
12. A modular building structure as in claim 11 wherein a portion of said collar member is adapted to surround at least a portion of said opening and engage the rim, and another portion of said collar includes means for receiving windows, doors and the like.
13. A modular building structure comprising a supporting structure including a plurality of spaced vertical columns, utilities integrated in said columns, horizontal beams interconnected between columns to form a rigid support system, a plurality of space modules each structurally defining an enclosed volume of space adapted to be removably supported from said frame, openings formed in said modules, a frame surrounding each of said openings, said modules being placed adjacent to one another with selected frames of adjacent modules being disposed in face to face relation to provide direct communication between modules, means connecting said selected face to face frames thereby directly interconnecting adjacent modules at said selected frames, means closing the openings defined by other frames of said module, means for detachably connecting the modules to said integrated utilities, and support means disposed between said frames and said supporting structure for supporting said modules from the supporting structure solely at said frame.
14. A modular building structure as in claim 13 wherein said frames include outwardly extending portions whereby the interconnected modules are spaced from one another to provide air circulation and sound isolation between modules.
15. A modular building structure as in claim 14 wherein said modules include curved outer surfaces to accommodate the supporting frame and utilities.
16. A modular building structure as in claim 15 including closure panels adapted to fit between adjacent modules to close the space between selected modules to form with said modules Roofs or walls of an enlarged space.
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GB1322674A (en) 1973-07-11
CA949280A (en) 1974-06-18
JPS521207B1 (en) 1977-01-13
DE2137375A1 (en) 1972-02-17
NL7110647A (en) 1972-02-07
FR2101192A1 (en) 1972-03-31
FR2101192B1 (en) 1975-07-11

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