Modular frame system using light-gage metal in building construction
Embodiments of the present invention provide a modular frame system for building construction using prefabricated frame components that can be assembled at the construction site easily and quickly. A number of connection mechanisms or joints are employed to connect the beams, columns, trusses, bases and the like. More specifically, they include connections for column to base, column to beam, truss/beam to column, truss to column, and truss to beam. In accordance with an aspect of the invention, a modular frame apparatus for building construction comprises a column; a plurality of prefabricated, modular structural components to be connected to the column; and a plurality of connecting mechanisms each configured and prefabricated to connect one or more of the plurality of modular structural components to the column in a modular manner to form a building module for a building.
The invention relates generally to modular building construction and, more particularly, to a modular frame system using light-gage metal in building construction and connection mechanisms for columns, beams, trusses, and other frame components designed to provide a modular assembly building construction that makes efficient use of materials and labor.
BACKGROUND OF THE INVENTIONModular building construction can have the advantages of cost-effectiveness and ease of assembly over convention building construction. Fully modular building frame systems, however, are still not commonly seen. As conventional building construction costs continue to escalate, modular building construction that can provide savings in cost of labor and materials presents an attractive alternative. The modular building components can be manufactured on-site or off-site, and then moved into position to form the building frame. There is a need for a more fully modular frame system that is easy and quick to construct and makes efficient use of materials and labor.
SUMMARY OF THE INVENTIONEmbodiments of the invention provide a modular frame system for building construction using prefabricated frame components that can be assembled at the construction site easily and quickly. A number of connection mechanisms or joints are employed to connect the beams, columns, trusses, bases and the like. More specifically, they include connections for column to base, column to beam, truss/beam to column, truss to column, and truss to beam. With proper design of these connections, the whole frame system can be modularized into relatively few standard sizes and types. The modular frame system is then used to construct a building with specially designed light gage metal studs, concrete slabs, and other prefabricated components. The frame system can be fully modularized, and the frame construction procedure is analogous to a furniture assembly process.
In accordance with an aspect of the present invention, a modular frame apparatus for building construction comprises a column; a plurality of prefabricated, modular structural components to be connected to the column; and a plurality of connecting mechanisms each configured and prefabricated to connect one or more of the plurality of modular structural components to the column in a modular manner to form a building module for a building.
In some embodiments, the modular structural components include a base. The connecting mechanisms include a column sleeve having an outer shape generally matching a shape of a hollow interior of the column and an outer size slightly smaller than a size of the hollow interior of the column to fit inside the column; a footing anchor fastener to fasten the column sleeve to the base; a height adjusting ring having a dimension generally matching the dimension of the hollow column and being disposed between the column and the base and being disposed around the column sleeve, the height adjusting ring having a height selected to adjust the height of the column relative to the base; and a column fastener to fasten the column to the column sleeve. The column sleeve includes an integrally formed nut; and the column fastener comprises a threaded bolt to threadingly engage the integrally formed nut to fasten the column to the column sleeve.
In specific embodiments, the column includes at least one slot in a column wall between an exterior and a hollow interior of the column. The modular structural components include a beam. The connecting mechanisms include a column connecting member attached to the beam, the column connecting member having a longitudinal body extending across and received into the slot of the column, and a transverse flange connected to the longitudinal body and having a slanted surface facing inwardly toward the beam; and a wedge-shaped choke configured to be disposed between the slanted surface of the transverse flange and the column wall. The wedge-shaped choke includes a slot to receive the longitudinal body of the column connecting member.
In some embodiments, the column includes a plurality of openings. The modular structural components include a beam. The connecting mechanisms include a pair of L-shaped beam holding bars attached to a hollow interior of the beam, the beam holding bars having threaded holes matching the holes on the column; and a plurality of fasteners configured to fasten the beam holding bars to the column via the holes of the beam holding bars and the holes on the column. The beam holding bars are disposed slightly inward from an end of the beam facing the column.
In some embodiments, the modular structural components include a beam. The connecting mechanisms include a tongue-in-groove connection The column includes one part of the tongue-in-groove connection and the beam includes another part of the tongue-in-groove connection.
In some embodiments, the column is a lower column. The modular structural components include an upper column to be disposed above the lower column. The connecting mechanisms include a transitional column sleeve having a shape generally matching shapes of the upper and lower columns and having a size slightly smaller than sizes of the upper and lower columns to fit inside hollow interiors of the upper and lower columns; and fasteners to fasten at least one of the upper and lower columns to the transitional column sleeve. The column transitional sleeve may include integrally formed nuts to be threadingly connected by the fasteners to fasten the column transitional sleeve to at least one of the upper and lower columns. The column transitional sleeve may include at least one slot matching at least one slot of one of the upper and lower columns. The column transitional sleeve may include a plurality of holes matching openings in at least one of the upper and lower columns.
In specific embodiments, the modular structural components include a truss or a beam. The connecting mechanisms include a holder having a holder base connected to the column and a pair of spaced holder supports extending from the holder base to receive the truss or beam therebetween, the pair of spaced holder supports each including an aperture for a fastener to pass therethrough to fasten the truss or beam to the pair of spaced holder supports. The column includes a column cap having a plurality of holes for connecting the holder base of the holder to the column cap via any one of the holes at selected location and orientation.
In some embodiments, the column includes at least one slot in a column wall between an exterior and a hollow interior of the column. The modular structural components include a truss. The connecting mechanisms include a column connecting member attached to the truss, the column connecting member having a longitudinal body extending across and received into the slot of the column, and a transverse flange connected to the longitudinal body and having a slanted surface facing inwardly toward the truss; and a wedge-shaped choke configured to be disposed between the slanted surface of the transverse flange and the column wall.
In specific embodiments, the column includes at least one slot in a column wall between an exterior and a hollow interior of the column. The modular structural components include a truss. The connecting mechanisms include a column connecting member attached to the truss, the column connecting member having a longitudinal body extending across and received into the slot of the column, a distal transverse flange connected to the longitudinal body to be disposed at an outer surface of the column wall, and a proximal transverse flange connected to the longitudinal body and having a slanted surface facing outwardly toward the distal transverse flange to be disposed adjacent an inner surface of the column wall; and a wedge-shaped choke configured to be disposed between the slanted surface of the proximal transverse flange and the inner surface of the column wall.
In some embodiments, the modular structural components include a truss. The connecting mechanisms include a beam connected to the column, the beam having a plurality of key slots; and a plurality of protrusions at an end of the truss to be received into the key slots of the beam.
In some embodiments, the modular structural components include a truss. The connecting mechanisms include a beam connected to the column, a holder base mounted to the beam, and a pair of spaced holder supports extending from the holder base to receive the truss therebetween, the pair of spaced holder supports each including an aperture for a fastener to pass therethrough to fasten the truss to the pair of spaced holder supports.
In specific embodiments, the column is formed by two column segments connected by a column extension sleeve. The modular structural components include a beam, and the beam is formed by two beam segments connected by a beam extension sleeve.
These and other aspects of the invention are described in further detail below and shown in the accompanying drawings.
1. Column to Base Connection
2. Column to Beam Connection
3. Truss/Beam to Column Connection
4. Truss to Column Connection
The connecting mechanisms of
5. Truss to Beam Connection
For the connecting mechanisms employing chokes in
Finally, a frame construction procedure utilizing the connection techniques described above is used to construct a modular frame. First, the base footing is poured with the footing anchor bolts 22 in place for the columns. The column sleeve 30 is installed over the footing on top of the anchor bolt 22. The next step is to adjust the position of the column sleeve 30, level the column sleeve 20, and to fix the column sleeve 30 in place using the washer 26 and nut 28. After all column sleeves 30 are fixed, a level is used to mark out the base line on each column sleeve 30. Adjusting rings 34 are selected for the column sleeves 30 to adjust the bottom of the corresponding columns to the desired elevation or base line height. The columns 10 are positioned over the column sleeves 30 to rest on top of the adjusting rings 34 or the footing if there is no need for an adjusting ring. At this time, the holes on the columns should line up with the fixing holes 36 of the column sleeves 30 and fasteners are used to fasten the columns 10 to the respective column sleeves 30.
The next step is to connect the beams 12 to the columns 10 using any of the connecting mechanisms described above (see, e.g.,
To add another story, upper columns are placed on top of the transitional column sleeves 100 or 110 and fastened together. Beams are connected to the upper columns and then permanently fixed. Floors are constructed on top of the installed beams. These steps are repeated until the top story is constructed and the roof level is reached.
For roof installation, the connection mechanism utilizing the column cap 120 and truss/beam holders 124 of
Although preferred embodiments of this invention have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.
Claims
1. A modular frame apparatus for building construction, comprising:
- a column;
- a plurality of prefabricated, modular structural components to be connected to the column; and
- a plurality of connecting mechanisms each configured and prefabricated to connect one or more of the plurality of modular structural components to the column in a modular manner to form a building module for a building.
2. The modular frame apparatus of claim 1
- wherein the modular structural components include a base;
- wherein the connecting mechanisms include a column sleeve having an outer shape generally matching a shape of a hollow interior of the column and an outer size slightly smaller than a size of the hollow interior of the column to fit inside the column; a footing anchor fastener to fasten the column sleeve to the base; a height adjusting ring having a dimension generally matching the dimension of the hollow column and being disposed between the column and the base and being disposed around the column sleeve, the height adjusting ring having a height selected to adjust the height of the column relative to the base; and a column fastener to fasten the column to the column sleeve.
3. The modular frame apparatus of claim 2 wherein the column sleeve includes an integrally formed nut; and wherein the column fastener comprises a threaded bolt to threadingly engage the integrally formed nut to fasten the column to the column sleeve.
4. The modular frame apparatus of claim 1
- wherein the column includes at least one slot in a column wall between an exterior and a hollow interior of the column;
- wherein the modular structural components include a beam; and
- wherein the connecting mechanisms include a column connecting member attached to the beam, the column connecting member having a longitudinal body extending across and received into the slot of the column, and a transverse flange connected to the longitudinal body and having a slanted surface facing inwardly toward the beam; and a wedge-shaped choke configured to be disposed between the slanted surface of the transverse flange and the column wall.
5. The modular frame apparatus of claim 4 wherein the wedge-shaped choke includes a slot to receive the longitudinal body of the column connecting member.
6. The modular frame apparatus of claim 1
- wherein the column includes a plurality of openings;
- wherein the modular structural components include a beam; and
- wherein the connecting mechanisms include a pair of L-shaped beam holding bars attached to a hollow interior of the beam, the beam holding bars having holes matching the openings of the column; and a plurality of fasteners configured to fasten the beam holding bars to the column via the holes of the beam holding bars and the holes on the column.
7. The modular frame apparatus of claim 6 wherein the beam holding bars are disposed slightly inward from an end of the beam facing the column.
8. The modular frame apparatus of claim 1
- wherein the modular structural components include a beam;
- wherein the connecting mechanisms include a tongue-in-groove connection; and
- wherein the column includes one part of the tongue-in-groove connection and the beam includes another part of the tongue-in-groove connection.
9. The modular frame apparatus of claim 1
- wherein the column is a lower column;
- wherein the modular structural components include an upper column to be disposed above the lower column; and
- wherein the connecting mechanisms include a transitional column sleeve having a shape generally matching shapes of the upper and lower columns and having a size slightly smaller than sizes of the upper and lower columns to fit inside hollow interiors of the upper and lower columns; and fasteners to fasten at least one of the upper and lower columns to the transitional column sleeve.
10. The modular frame apparatus of claim 9 wherein the column transitional sleeve includes integrally formed nuts to be threadingly connected by the fasteners to fasten the column transitional sleeve to at least one of the upper and lower columns.
11. The modular frame apparatus of claim 9 wherein the column transitional sleeve includes at least one slot matching at least one slot of one of the upper and lower columns.
12. The modular frame apparatus of claim 9 wherein the column transitional sleeve includes a plurality of holes matching openings in at least one of the upper and lower columns.
13. The modular frame apparatus of claim 1
- wherein the modular structural components include a truss or a beam;
- wherein the connecting mechanisms include a holder having a holder base connected to the column and a pair of spaced holder supports extending from the holder base to receive the truss or beam therebetween, the pair of spaced holder supports each including an aperture for a fastener to pass therethrough to fasten the truss or beam to the pair of spaced holder supports.
14. The modular frame apparatus of claim 13 wherein the column includes a column cap having a plurality of holes for connecting the holder base of the holder to the column cap via any one of the holes at selected location and orientation.
15. The modular frame apparatus of claim 1
- wherein the column includes at least one slot in a column wall between an exterior and a hollow interior of the column;
- wherein the modular structural components include a truss; and
- wherein the connecting mechanisms include a column connecting member attached to the truss, the column connecting member having a longitudinal body extending across and received into the slot of the column, and a transverse flange connected to the longitudinal body and having a slanted surface facing inwardly toward the truss; and a wedge-shaped choke configured to be disposed between the slanted surface of the transverse flange and the column wall.
16. The modular frame apparatus of claim 1
- wherein the column includes at least one slot in a column wall between an exterior and a hollow interior of the column;
- wherein the modular structural components include a truss; and
- wherein the connecting mechanisms include a column connecting member attached to the truss, the column connecting member having a longitudinal body extending across and received into the slot of the column, a distal transverse flange connected to the longitudinal body to be disposed at an outer surface of the column wall, and a proximal transverse flange connected to the longitudinal body and having a slanted surface facing outwardly toward the distal transverse flange to be disposed adjacent an inner surface of the column wall; and a wedge-shaped choke configured to be disposed between the slanted surface of the proximal transverse flange and the inner surface of the column wall.
17. The modular frame apparatus of claim 1
- wherein the modular structural components include a truss; and
- wherein the connecting mechanisms include a beam connected to the column, the beam having a plurality of key slots; and a plurality of protrusions at an end of the truss to be received into the key slots of the beam.
18. The modular frame apparatus of claim 1
- wherein the modular structural components include a truss; and
- wherein the connecting mechanisms include a beam connected to the column, a holder base mounted to the beam, and a pair of spaced holder supports extending from the holder base to receive the truss therebetween, the pair of spaced holder supports each including an aperture for a fastener to pass therethrough to fasten the truss to the pair of spaced holder supports.
19. The modular frame apparatus of claim 1 wherein the column is formed by two column segments connected by a column extension sleeve.
20. The modular frame apparatus of claim 1
- wherein the modular structural components include a beam; and
- wherein the beam is formed by two beam segments connected by a beam extension sleeve.
21. A system for coupling a column to a base comprising:
- a column sleeve having an outer shape generally matching a shape of a hollow interior of the column and an outer size slightly smaller than a size of the hollow interior of the column to fit inside the column;
- a footing anchor fastener to fasten the column sleeve to the base;
- a height adjusting ring having a dimension generally matching the dimension of the hollow column and being disposed between the column and the base and being disposed around the column sleeve, the height adjusting ring having a height selected to adjust the height of the column relative to the base; and a column fastener to fasten the column to the column sleeve.
22. The system of claim 21 wherein the column sleeve includes an integrally formed nut; and wherein the column fastener comprises a threaded bolt to threadingly engage the integrally formed nut to fasten the column to the column sleeve.
23. A system for coupling a column to a beam comprising:
- a column connecting member coupled to the beam, said column connecting member having a longitudinal body extending across and received into a slot of the column, and a transverse flange connected to the longitudinal body and having a slanted surface facing inwardly toward the beam; and
- a wedge-shaped choke configured to be disposed between the slanted surface of the transverse flange and the column wall.
24. The system of claim 23 wherein the wedge-shaped choke includes a slot to receive the longitudinal body of the column connecting member.
Type: Application
Filed: Jun 28, 2007
Publication Date: Jan 1, 2009
Inventor: James Zhai (Walnut, CA)
Application Number: 11/823,777
International Classification: E04B 1/00 (20060101);