COMPOSITE BUILDING MODULE WITH A THERMAL MASS RADIATOR

Abstract

A precast monolithic concrete prefabricated, composite building construction module formed of a substantially planar rear wall. The rear wall has embedded therewithin a radiator pipe for circulating a fluid at a temperature that is different from an ambient temperature of the modular component within the rear wall. The module may comprise at least one side wall integral with the rear wall that terminates at one end at a corresponding end of the rear wall. The rear wall has a length and each of the at least one side walls has a length and extending in a first direction substantially normally away from the rear wall sufficient to substantially enclose and define walls of a standard facility, the at least one side wall supporting the rear wall to cause the module to be free-standing while devoid of lateral support. The radiator pipes are interconnected through inlet/outlet junctions by tubing with other inlet/outlet junctions to permit a single circulating fluid source to circulate fluid through the radiator pipes of a plurality of the modules making up a building structure.

Description

TECHNICAL FIELD

The present disclosure relates to construction modules and in particular to a composite construction module with integrated heating and cooling capability.

INTRODUCTION

Despite numerous innovations in materials, construction techniques have evolved slowly over a number of centuries. Construction has remained labour intensive and highly reliant on the skill of tradespeople. As a result, construction and finishing costs remain high and delays in securing tradespeople remain a significant concern in undertaking a building project. A number of attempts at reducing costs and delays have been proposed involving the use of prefabrication techniques. These have not been generally embraced by the construction industry.

Commonly assigned [STILL TO DO] Canadian Patent No. 1,186,524 issued May 7, 1985 to Teron (“Teron No. 1”) and entitled “Modular Building System”, which is incorporated by reference in its entirety herewith, discloses a building module, modular building constructions and methods for erecting same. The module is of deep U-shape configuration, defining a space which is able to enclose various facilities within a building structure. A typical module includes a top channel and an internal conduit system for power and/or communications systems and the like. The modules can be quickly erected in a wide variety of arrays and configurations to provide exterior walls and to enclose and define interior space. Teron No. 1 provides a mechanism for economical design and construction of a wide variety of building layouts using a small number of similar and easily produced finished surface components, and also makes provision for prefabrication of appurtenances and facilities. Teron No. 1 also provides for both installation of electrical power and communications systems through a series of integral conduits and raceways within each module.

Canadian Patent No. 2,144,938 issued May 29, 2007 to Teron (“Teron No. 2”) and entitled “Method Of Manufacturing Building Modules And Structures Formed Thereby”, which is incorporated by reference in its entirety herein, discloses a molding assembly comprising a U-shaped mesh, U-shaped formwork and pieces removably fixed to opposite edges of the mesh in parallel planes orthogonal to planes of the U-shaped mesh, the framework end pieces having a width at least as thick as walls of a U-shaped module to be cast therebetween and enveloping the mesh, and having opposite edges containing the mesh therebetween.

Other building system components such as heating and cooling systems are not easily accommodated in the Teron No. 1 module or by prefabrication techniques. Rather, ductwork and conventional HVAC systems are installed separately in the construction. Such systems are expensive to obtain, install and operate, especially in the current regime of high energy costs.

Radiant heating flooring systems are also conventionally installed in new construction by casting radiator pipes into the concrete slabs. Both are typically installed at considerable cost in terms of fabrication and installation of piping and connections to a supply system.

An attempt to introduce radiant heating coils in small building projects would not be cost effective.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of an example embodiment of a composite building construction module with an integral thermal mass radiator;

FIG. 2 is an isometric view of a plurality of the modules of FIG. 1, with radiator pipes connected and supplied by a circulating fluid source according to an example embodiment of the present disclosure;

FIG. 3A is a plan view of an example embodiment of the module of FIG. 1 with only one side wall and with multiples of n and p taking on values of 3 and 1 respectively;

FIG. 3B is a plan view of an example embodiment of the module of FIG. 3A with multiples of n and p taking on values of 4 and 1 respectively;

FIG. 3C is a plan view of an example embodiment of the module of FIG. 1 with no side walls;

FIG. 4 is a plan view illustrating an example embodiment of a joint sealing mechanism between portions of example embodiments of adjacent modules;

FIG. 5A is a plan view of an example embodiment of the module of FIG. 1 with multiples n and p taking on values of 2 and 1 respectively;

FIG. 5B is a plan view of an example embodiment of the module of FIG. 1 with multiples n and p taking on values of 3 and 1 respectively;

FIG. 5C is a plan view of an example embodiment of the module of FIG. 1 with multiples n and p taking on values of 4 and 1 respectively;

FIG. 5D is a plan view of an example embodiment of the module of FIG. 1 with multiples n and p taking on values of 5 and 1 respectively;

FIG. 5E is a plan view of an example embodiment of the module of FIG. 1 with multiples n and p taking on values of 6 and 1 respectively;

FIG. 5F is a plan view of an example embodiment of the module of FIG. 1 with multiples n and p taking on values of 2 and 1.5 respectively;

FIG. 5G is a plan view of an example embodiment of the module of FIG. 1 with multiples n and p taking on values of 3 and 1.5 respectively;

FIG. 6 is a front right isometric view of an example embodiment of the module of FIG. 1, with an opening for a window panel;

FIG. 7A is an isometric view of an example embodiment of the module of FIG. 1 illustrating an example embodiment of a wiring arrangement utilizing a top indentation and separate interior conduit system, with radiator pipes removed for clarity;

FIG. 7B is a fragmentary section of one of the module side walls of FIG. 7A; and

FIG. 8 is an exploded perspective view, showing an example layout of example embodiments of the modules of FIG. 1 in a single story structure or one level of a multi-storey structure.

Like reference numerals are used in the drawings to denote like elements and features.

DESCRIPTION

The present disclosure provides an example embodiment of a composite building construction thermal mass radiator module that may be used in building construction of primarily residential premises. The module provides not only a construction element, but an economical and effective heating and cooling system that may be incorporated with any number of conventional and innovative “green” heating and cooling technologies. The module thus forms part of a total composite building system. As disclosed herein, it performs multiple functions, including, without limitation, acting as the structural element for a building, acting as a modular thermal mass radiator with its own heating and cooling coils, providing a high quality pre-finished wall surface, providing a functional container for various residential functions such as kitchen, bathroom, closet, and entire rooms, and providing a universal system of electrical and communications conduits. Further, the module provides improved fireproofing, soundproofing and earthquake tolerance over wood or steel stud-framed structures.

The present disclosure describes a precast monolithic concrete prefabricated, composite building construction module formed of a substantially planar rear wall. The rear wall has embedded within it a radiator pipe for circulating a fluid at a temperature that is different from an ambient temperature of the module. The use of radiator pipes embedded in the wall during forming of the pre-cast module significantly reduces the cost, labour and time to provide a radiant heating system, in part by substantially eliminating both any additional form work, and any construction after-market work by contractors, and allows its implementation across a broad cross-section of building layouts, in terms of size, complexity and function.

By using a composite modular wall system with radiant piping embedded within a rear wall of each component module, the modules may be mass produced at a remote facility using a single and reusable high quality steel mold. This greatly reduces the cost of manufacture, and as well allows for pre-engineering, pre-fabrication and pre-installation of the radiant piping and the heating/cooling capability provided thereby, on a high repeat production basis in a factory using less costly factory labour. As a result, each composite modular unit may be then delivered to a construction site and lifted and erected on-site in a single process, allowing for simple interconnection and connection to a supply system to provide a complete heating/cooling system integral to the erection of the modular structure.

Furthermore, installation is quick and easy, substantially involving only lifting the module into position and connecting a number of inlet/outlet pipe connections, all of which are externally accessible.

Heating and cooling costs for buildings incorporating such modules may be significantly reduced and the burden on the existing energy grid(s) may be substantially eased.

In some embodiments, the module may have at least one substantially planar side wall integral with the rear wall.

The rear wall has a length sufficient to span a major portion of a room and each of the at least one side walls has a length sufficient to define and enclose, with the rear wall, a standard facility (which may include any of the standard appurtenances commonly used in residential building construction, including, without limitation, kitchen counters, cupboards, appliances, bathroom counters, bathtubs, shower stalls, closets, fireplaces) and extending in a first direction substantially normally away from the rear wall such that the rear wall may be free-standing while substantially devoid of lateral support. In some example embodiments, an effective centre of mass of the module is located beyond the rear wall in the first direction.

Such modules, which may be in the form of a U-shaped module having two side walls, an L-shaped module having one side wall and an in-fill panel having no side walls may be used in combination to define rooms on a floor surface and to form a building structure. In particular, in-fill panels may be spaced apart from other modules to form gaps into which doors and windows may be fixed. Such modules may be connected to the floor surface by means of centering inserts inserted in vertically extending apertures in the floor surface that are accepted by integrally formed bearing pads in the walls of the modular components.

Referring now to FIG. 1, there is shown a construction module 100 comprising a precast concrete unitary structure having a planar rear wall 110.

The use of concrete as the primary construction component of the module 100 provides some advantages with regard to heating and cooling. Concrete is recognized as a material that has a high capacity to absorb and store heat and is one of the main contributors to the thermal mass of a building structure.

Thermal mass is considered to be a measure of a structure's ability to store and regulate internal heat. A structure with high thermal mass will heat up slowly, but concomitantly will cool down slowly as well. For purposes of energy conservation this is considered advantageous because the structure effectively acts like a heating/cooling battery in that it stores and releases heat slowly, moderating fluctuations in temperature. Thus, structures comprised of predominantly concrete, such as the module 100, have a high thermal mass, especially when compared to hollow concrete or brick and especially steel structures and walls comprised of wood or metal studs and drywall.

While thermal mass concrete is conventionally energized by passive means such as passive solar heating and daylight, in the present disclosure, the benefits of a high thermal mass concrete module 100 is considerably increased by incorporating within the rear wall 110, a continuous length of hollow radiator pipe 150 sufficient to radiate or to sink a desired amount of heat. The radiator pipe 150 extends between an inlet/outlet junction 151 accessible from beyond the module 100.

The radiator pipe 150 is filled with fluid such as, for example, water or glycol, which circulates through the radiator pipe 150 at a temperature that is different from the ambient temperature of the module 100. In the winter, heating the fluid passing through the radiator pipe 150, for example by a hot water heater, allows the rear wall 110 and to a lesser extent the side wall(s) 120 of the module 100 to absorb and radiate heat. As the ambient temperature cools, especially at night, the module 100 releases this heat internally (and to some extent externally) within the structure and moderates the cooling effect of the change in temperature.

In the summer, heat energy absorbed by the rear wall 110 and side walls 120 of each module 100 during the day will tend to be moderated by the relatively cooler night temperature from the previous evening. This summer cooling effect can be significantly accentuated through the circulation of cooled fluid through the radiator pipe 150.

In some example embodiments, the radiator pipe 150 assumes a serpentine or undulating pattern that extends substantially across the entire rear wall 110. In some example embodiments the radiator pipe 150 comprises a series of coils buried within the rear wall 110. In some example embodiments, the radiator pipe 150 may be comprised of ½ inch, ¾ inch or 1 inch piping, typically composed of flexible plastic.

In some example embodiments, the module 100 may also have one or two planar side walls 120 extending substantially normally outwardly from each of the opposing side edges of rear wall 110. Thus, the module 100 may have a generally U-shaped or L-shaped configuration.

In some example embodiments the inlet/outlet junction 151 is disposed on the side wall(s) 120 proximate to the rear wall 110.

The radiator pipe 150 may be interconnected through the inlet/outlet junctions 151 by fixed or flexible tubing to an inlet/outlet junction 151 of an adjacent or proximate module 100 either directly or by an external fluid connection such as a pipe or hose (not shown) so as to permit a single circulating fluid source 200 (FIG. 2) such as a hot water tank connected to an inlet/outlet junction 151 of one of the modules 100 to circulate fluid through the radiator pipe 150 in the rear walls 110 of a plurality of the modules 100 making up a structure, providing significant heating and cooling benefit.

In some example embodiments, the inlet/outlet junction 151 may comprise a spliced connection comprising a coupler secured by one or more compression rings and/or solder, a tap, a hose, a valve, or an externally threaded (male) connection and an internally threaded (female) connection. In some example embodiments, a plurality of circulation loops or heating/cooling zones may be established by careful attention to which module 100 is connected to which, In multi-storey structures, each storey may be allocated its own circulation loop(s). In some example embodiments, and in some layout configurations of the module 100, a circulation loop may comprise a plurality of flow paths at some points.

The extremely high thermal mass of the structure from its constituent modules 100, all of whose radiator pipes 150 are linked in one or more circulation loops, allows a small boiler 200 (FIG. 2) to provide significant heating capability with great efficiency. Indeed, preliminary estimates suggest that a comfortable environment in adverse weather conditions may be obtained with only intermittent use of a small boiler in such fashion. Similarly, in summer, the radiator pipes are linked to a cooling source.

There are many known methodologies for providing a circulating source of fluid of different temperature 200, including without limitation, solar panels for heating coils of fluid (solar water heaters), air conditioning units, refrigeration units, heat pumps, geothermal heat pumps for pumping relative warmer fluid from beneath the earth's surface during the winter and relatively cooler fluid during the summer, inline or tankless water heaters, and conventional oil, natural gas and electrical hot water tanks, any of which may be incorporated with the module 100. When used with solar, geothermal or similar renewable technologies, the radiator pipe 150 in the rear wall 110 of the module 100 provides a renewable energy distribution system.

In some example embodiments, the circulating fluid source 200 may be the same as or separate from the structure's existing hot water tank.

Circulation of the fluid may be achieved through convection or gravity, or may be assisted by the use of one or more circulating pumps (not shown) which may be incorporated within or separate from the circulating fluid source 200.

The use of the module 100 as a modular thermal mass radiator as disclosed herein allows it to be an integrated part of a total HVAC system in the building structure constructed from it, with appropriate connection between modules 100 and their supply sources, into which thermostatic and monitoring controls (not shown) may be incorporated.

In some example embodiments, the radiator pipe 150 may be installed within the side wall(s) 120 or floor slab in addition to the rear walls 110.

Each of the side walls 120 has a facing interior side wall surface 121 and an opposed exterior side wall surface 122 that are substantially parallel. The interior side wall surfaces 121 are separated by an interior rear wall surface 111 and the exterior side wall surfaces 122 are separated by an exterior rear wall surface 112 which is substantially parallel to the interior rear wall surface 111. In some example embodiments, the thickness of the rear wall 110, that is, the separation between the interior rear wall surface 111 and the exterior rear wall surface 112 and the thickness of the side walls 120, that is, the separation between an interior side wall surface 121 and the corresponding exterior side wall surface 122 may be substantially 4¾ inches. In some example embodiments, the thickness of the rear wall 110 and the side walls 120 may be greater or smaller than this amount. In some example embodiments, the wall thickness is sufficient to provide mechanical strength and so as to accommodate the radiator pipes 150 and inlet/outlet junctions 151, as well as internal reinforcing rods, conduits 700, 730, 731, 740 and junction boxes 710, 711, 712, 732 (FIGS. 7A, 7B) as described herein. In some example embodiments, the inlet/outlet junctions 151 are accessible from the external side wall surface 122.

In some example embodiments, the module 100 may be formed by the pouring of concrete into a mold, which may in some example embodiments may be oriented with the side wall(s) 120 facing downward. In some example embodiments, subject to minor constraints imposed by the addition of radiator pipes 150 and inlet/outlet junctions 151, as well as conduits 700, 730, 731, 740 (FIGS. 7A, 7B) and junction boxes 710, 711, 712, 732 as described herein, steel reinforcing rods and steel mesh may be embedded within the concrete. Such an approach is disclosed in Teron No. 2, which is incorporated by reference in its entirety herein.

Modules with one side wall 120, that is an L-shaped module 100′or a flat in-fill panel, with no side walls 120, that is a flat in-fill panel 100″ (with the U-shaped module collectively referred to as “module 100”) may be constructed in some example embodiments from the same molds as the U-shaped module 100, simply by inserting one or two blocks, as the case may be, into the mold at an appropriate position to preclude the creation of one or both side walls 120. In some example embodiments, such modules 100′ and 100″ may be useful if spaced apart from other modules 100 in order to create gaps in the layout of the building. In some example embodiments, doors or windows or both may be fixed in the gaps thus formed.

Example embodiments of an L-shaped module 100′ with one side wall 120 are shown in FIGS. 3A and 3B. It will be apparent that even though the right side wall 120 is shown in these example embodiments, an L-shaped module 100′ may be created and used having a left side wall 120 without departing from the spirit and scope of the present disclosure. Example embodiments of a flat in-fill panel 100″ are shown in FIG. 3C.

The modules 100 are composite multi-task products that may be mass-produced in a variety of sizes using a single mold, without regard to the function to which it will be put and irrespective of in which apartment, building, project or country it may be used. The availability of multiple sizes and configurations of modules 100 provides the flexibility to easily service an almost infinite range of building plans and arrangements demanded by a (geographically, culturally and architecturally) diverse marketplace.

Because of the modular nature of the modules, a single mold is used and reused many times in the factory. Accordingly, the mold may be a relatively more expensive but high quality and precise open steel mold, which is vibrated and trowelled to provide precise dimensional stability and a high quality final surface finish to both the inner walls 111, 121 and exterior walls 112, 122, not generally available with conventional concrete forming techniques, that can accommodate an interior finish such as paint or wallpaper or an exterior finish such as paint, or a cladding of wood, aluminum, vinyl, brick or stone, without significant or any additional surface preparation. The multiple use of steel molds significantly reduces the forming costs for each building.

The finished surface may be continued by sealing the exposed interior and exterior joints created by the approximately ¼ inch gap between modules 100. As is shown in FIG. 4, a finished interior joint 400 may be obtained from conventional taping, plastering and sanding over the finished concrete surface of adjacent walls 110, 120. Exterior joints may be sealed by fitting a flexible rain shield, such as a PVC strip or bead 420 disposed in the vertical joint, covered and sealed with a bead of exterior caulking 430.

In some example embodiments, exterior wall surfaces 112, 122 may be provided with an insulating layer such as rigid insulation board, with or without a vapor barrier under the exterior finish. In such fashion, the insulating layer may be disposed on the exterior wail surfaces 112, 122 where it achieves its full effectiveness. It will be noted that conventional precast construction, which involves the use of expensive, time-consuming custom casting molds, typically out of wood, does not provide a high quality final surface finish. As such, the insulation is typically placed against the less effective interior surface, because steps will be thereafter be taken to finish the interior surface by the application of drywall and the like and the exterior surface is left rough and sometimes exposed.

Thus, the use of a single mold to produce the modules 100 eliminates many layers of construction materials and many steps of labour. This provides an improved cost/benefit ratio in terms of both quality and quantity of said product heretofore not achievable by conventional on-site construction techniques.

In some example embodiments, the concrete may be prestressed.

In some example embodiments, the radiator pipe 150 may be interspersed among and between the steel bars and wire meshing for reinforcing the concrete module 100. In some example embodiments, and subject to any engineering constraints, the radiator pipe 150 may be substituted for such rebar or steel meshing or provide additional reinforcing support to the concrete module 100.

The use of such a mold considerably simplifies the process of installing the radiator pipe 150 within the rear wall 110. The radiator pipe 150 may simply be laid down in a rear wall portion of the mold in a desired pattern that leaves the inlet/outlet junction 151 externally accessible. In some example embodiments, the layout of the radiator pipe 150 may be chosen to avoid obstructing the position of the reinforcing rods, mesh and conduits 700, 730, 731 and 740 and junction boxes 710, 711, 712, 732 as described herein. The entire package of radiator pipes and inlet/outlet boxes may also be pre-assembled, mass-produced, and then dropped into the mold, thus reducing labour costs.

In some example embodiments, the side walls 120 are provided with a small degree of draft between their interior side wall surfaces 121 and their corresponding exterior side wall surfaces 122 in order to facilitate stripping of the module 100 from the molds, without significantly impacting the basic “squareness” of the side walls 120 relative to the rear wall 110.

In some example embodiments, the intersection between the interior rear wall surface 111 and one of the interior side wall surfaces 121 may be rounded to provide added strength, a more aesthetically pleasing appearance and to provide ease of cleaning the wall surfaces.

In use, the modules 100 are oriented for installation to be vertically positioned with a bottom end 140 of the rear wall 110 and side walls 120 (as appropriate) against a horizontal floor surface 10.

In some example embodiments, the bottom end of the rear wall 110 and side walls 120 (as appropriate) of each module 100 may be provided with a plurality of corner bearing pads 113 at the intersection between the rear wall 110 and the side wall 120 and side wall bearing pads 123 at the distal end of the side wall 120, with elongated recessed regions 114, 124 between adjacent corner bearing pads 113 and between corner bearing pads 113 and their adjacent side bearing pads 123 respectively. The recessed regions 114, 124 provide room for a grouting compound to be inserted between the module 100 and the floor surface 10 on which it is standing to satisfy building codes including but not limited to fire, water and insect resistance codes, as well as to improve the structural stability of the module 100 when in upright position. In some example embodiments, the corner bearing pads 113 and side bearing pads 123 may be integral to the module 100.

In some example embodiments, the height h of the module 100 may correspond to a number q of stories S according to governing building codes. In some example embodiments, for typical North American residential construction, a storey may be considered to be substantially 8 feet in height. In some example embodiments, the number q may be an integer or a half-integer.

In some example embodiments, the length l of the module 100 along the rear wall 110 and the width w of the module 100 along the side walls 120 (as appropriate) may each be multiples, respectively designated n and p, of a modular dimension M. In some example embodiments, the multiples n and p may be integers or half-integers. In some example embodiments, for typical North American residential construction, the modular dimension M may be 32 inches (80 cm) so that one half of that dimension corresponds to typical stud spacing in North American residential construction. In some example embodiments, with such modular dimension, typical side wall dimensions may vary from 0 inches up to 48 inches (1.5 M), with some example embodiments of modules 100 having a side wall dimension of 24 inches (0.075 M) to accommodate fixtures and appurtenances. In some example embodiments, the modular dimension M may be 36 inches. In some example embodiments, for other countries, the modular dimension M may be 90 cm.

Thus, with side walls 120 with a multiple p of only 1, the module 100, 100′ imparts free-standing stability by shifting the centre of gravity beyond and in front of the interior rear wall 111. By so displacing the centre of gravity, the modules 100 and 100′ may be created and erected on-site and are capable of standing alone without the use of braces or side construction elements.

A side wall 120 multiple p of 1 also substantially completely encloses most residential architectural features, including but not limited to interior doorways, hallways, balconies, windows, closets, countertops, sinks and fireplace inserts, as well as typical appurtenances and facilities, including but not limited to showers, bathtubs, shelving and entertainment units, desks, furniture, household equipment, office equipment, retail showcases and some major appliances.

The length l of the rear wall 110 may be, in some example embodiments, a multiple n of 2, 3, 4, 5 or 6 to provide a suitable variety of design options with relatively few different sized modules 100. It has been found that between three to five basic configurations of the module 100 provide for a wide flexibility in design.

Turning now to FIGS. 5A through 5G, there are shown example embodiments of modules 100 having different configurations based on different integer or half-integer values of multiples n and p. The configurations are shown against the background of an imaginary square grid in which the solid lines represent integer spacing of the modular dimension M and the dashed lines represent half-integer spacing of the modular dimension M, as are the configurations of FIGS. 3A and 3B.

With a side wall 120 with a multiple p of the half-integer 1.5, such as shown in FIGS. 5F and 5G, wider features such as shower and tub enclosures may be better accommodated. In some example embodiments, multiple p may be constrained to an integer or half-integer value of 1 or greater.

In some example embodiments, the appurtenances and facilities may be prefabricated and installed within the corresponding module 100 at an off-site location and shipped to the building site for connection to other modules 100. Such prefabrication allows consolidation of skilled tradespeople at off-site locations which may improve quality and reduce cost and construction delays.

In many design configurations, the free-standing nature of adjacent modules 100, 100′ do not use mutual reinforcement or bracing, as indicated above. However, to provide for proper fit between adjacent modules 100, in some example embodiments, as shown in FIG. 5A, each module 100 is dimensioned such that its outer surfaces 112, 122 are spaced inwardly of such dimensions by a small amount, which may be, in some example embodiments, ⅛ inch. That is, each module 100 is approximately ¼ inch less in each dimension than would be otherwise understood.

In some example embodiments, standard door and window units may be of a size which correspond to integer or half integer multiples of the modular dimension M so that they may simply be substituted for panels 100″ in the layout of a building between modules 100 in gaps defined by spacing apart modules 100. Such door and window units may be connected to the modules 100 using connectors well known in the construction industry for connection to concrete structures. The placing of doors and windows, adjacent to modules 100, permits design flexibility beyond that that would be achievable if they were simply cast into the modules 100 or placed within openings cut within them and provide an open system which responds to local user preferences, standard accoutrements and local practices and site conditions. This permits the modules 100 to function as part of an open building system that accepts and utilizes existing building components such as building equipment and fixtures and standard doors and windows.

In some example embodiments, the panels 100″ may be made with a height h which is less than a storey q so that a window may be situated above the panel 100″.

In some example embodiments, because of designer preference, one or more of the modules 100 may have openings 610 cut within them to accommodate windows, such as is shown in an example embodiment in FIG. 6. In such example embodiments, the layout of the radiator pipes 150 may be adjusted to avoid the openings 610, with substantially insignificant impact on the heating or cooling effect provided.

In some example embodiments, electrical power and communications capability (including without limitation telephone, cable and Internet connectivity) may be provided to the modules 100 by a series of embedded conduits in the module 100 such as is shown in FIG. 7A and 7B.

In some example embodiments, a trough-like raceway 131 extends along a top end 130 of the side walls 120 and the rear wall 110. The raceway 131 may be of sufficient width to accommodate one or more electrical cables and may, in some example embodiments, be about 1¼ to 2 inches in depth.

In some example embodiments, communications capability may be provided by vertically extending conduits 700 terminating at an upper end at a junction box 710 just below opposing end portions of raceway 131. Conduits 700 extend vertically downward through the side walls 120 (in some example embodiments, the rear wall 110) and pass through one or more junction boxes strategically located at various heights, (such as the intermediate junction box 711 and lower junction box 712 shown in the example embodiment of the Figure) and open into the recess 124 between the side bearing pad 123 and its adjacent corner bearing pad 113.

Top conduit 700 may be disposed approximately mid-way between opposing surfaces 121, 122 of the side wall 120. The junction boxes 710, 711, 712 are disposed such that their sides are spaced from the surfaces 121, 122 of the side wall 120 by relatively short distances with relatively thin layers of concrete overlying them. Thus, when access is sought to a junction box 710, 711, 712, the thin concrete cover may be chipped away and a side plate of the junction box 710, 711, 712 removed, to provide access to the junction box 710, 711, 712 to effect electrical connections. In some example embodiments, the top junction box 710 communicates directly with the raceway 131.

A transverse conduit 730 extends in the horizontal direction through side walls 120 as well as rear wall 110, the opposing ends of transverse conduit 730 entering top junction boxes 710. In some example embodiments, a further transverse conduit 731 extends horizontally through side walls 120 and rear wall 110 between bottom junction boxes 712 and a junction box 732 spaced intermediate between the interior rear wall 111 and the exterior rear wall 112, at a convenient height so as to be useable in connection with a wall switch or appliance outlet.

By positioning the majority of conduits 700, 730, 731, 740 and junction boxes 710, 711, 712, 732 within the side walls 120, interference with the radiator pipes 150 is minimized. To the extent that the conduits 731 and the junction boxes 732 lie within the rear wall 110, the layout of the radiator pipes 150 may be adjusted to avoid them, with substantially insignificant impact on the heating or cooling effect provided.

Because all of the various junction boxes 710, 711, 712, 732 are accessible from both the interior and exterior wall surfaces, virtually regardless of how the individual modules 100 are arranged in any particular building configuration, the junction boxes 710, 711, 712, 732 will be readily accessible. In some example embodiments, the module 100 may be prewired to reduce the amount of on-site work.

Where modules 100 are closely adjacent to one another, one component may be electrically connected to the other by chipping away the thin concrete covering respective junction boxes in each component and electrically interconnecting the junction boxes.

Where two modules 100 are not immediately adjacent to each other, such as when separated by a window or door, cable may be passed along the lintels of the windows, or through a dropped ceiling space of the structure as appropriate and available.

With such features, a wide variety of layout configurations may be created to suit any style or constraint. FIG. 8 is an example embodiment of a layout illustrating the position of various modules 100 into a single storey application. The modules 100 are positioned on a floor surface 10, which may, in some example embodiments, be a precast or poured concrete slab or slabs on grade. For purposes of illustration, the floor surface 10 is shown as having an imaginary square grid defined thereon consisting of two series of parallel lines intersecting one another at right angles, which lines are spaced apart by a distance corresponding to the modular dimension M. It should be noted that the use of the grid is for illustrative purposes only and that the modules 100 may be dimensioned and positioned with total freedom and need not be constrained to integer and half-integer multiples of the modular dimension M on a square grid. Nevertheless it has been found that working with integer and half-integer multiples of M disciplines the design process in an advantageous manner.

A first group of modules 100 may be positioned relative to one another on the floor surface 10 adjacent perimeter portions of such surface so as to define portions of the side walls of the building. A further group of the modules 100 are positioned on the floor surface 10 interiorly of the perimeter portions to define at least portions of the interior partitions of the building.

Careful consideration of FIG. 8 will demonstrate that the various modules 100, in different configurations, including, without limitation, those shown in FIGS. 3A and 3B and 5A through 5G, serve to provide partial space enclosures to house or partly enclose the various facilities during building construction.

In some example embodiments the designed layout of the modules 100 may be given effect by physically marking a square grid pattern corresponding to the size of the modular dimension M on the horizontal surface and the proposed module 100 locations and configurations marked thereon. Thereafter, the location of the apertures in the corner bearing pads 113 and side bearing pads 123 may be accurately marked. In some example embodiments, the locations of the apertures may be accurately determined by superimposing reusable templates for modules 100 of appropriate configuration, on which the aperture locations have been marked, over the grid at the appropriate location.

In some example embodiments, a lifting device (not shown) may be employed to lift the module 100 with lifting hooks anchored into suitably located apertures (not shown) so that the module 100 hangs plumb.

Once all of the modules 100 have been erected, a further set of flat concrete slabs, forming a floor surface 10 of an upper storey or alternatively a roof structure may be positioned over and supported by the top portions of the modules 100. The modules 100 of upper stories may be erected in like manner. The load of the floor surface(s) 10 and roof structure is carried downwardly to the lowermost floor surface 10 or footing via the walls 110, 120 of modules 100 including both the ones positioned around the perimeter of the floor surface 10 and defining the exterior of the structure and those positioned interiorly to lay out the interior partitions of the structure. The lower ends of the modules 100 are secured to the floor surface 10 immediately below and the floor surface 10 or roof structure supported on a plurality of modules 100 are secured to the modules 100 by connections such as are known in the art. The number of stories depend on a number of factors identified in conventional engineering and job considerations, including, without limitation, span length of the floor surface(s) 10, expected live loads and the type of connections provided, seismic considerations and geo-technical (soil) conditions.

In some example embodiments, the modules 100 used to define the exterior of the structure may be constructed of multiple storey components (q1) and upper floor surfaces 10 extending between and within such exterior modules 100. In some example embodiments, angle brackets such as are known in the art may be used to attach the intermediate floor surfaces 10 to the multiple storey external modules 100.

Thus, the prefabricated nature of the modules 100, with integral and prefabricated networks of radiator pipes 150 and conduits 700, 730, 731, 740 contained within them permit quick, easy and inexpensive erection of a wide variety of structures using only a lift and calling for only minimal interconnections of radiator pipes 150 and conduits 700, 730, 731, 740 on-site.

While the present disclosure is sometimes described in terms of methods, the present disclosure may be understood to be also directed to various apparata including components for performing at least some of the aspects and features of the described methods. Moreover, an article of manufacture for use with the apparatus may direct an apparatus to facilitate the practice of the described methods. Such apparatus and articles of manufacture also come within the scope of the present disclosure.

The various embodiments presented herein are merely examples and are in no way meant to limit the scope of this disclosure. Variations of the innovations described herein will become apparent from consideration of this disclosure and such variations are within the intended scope of the present disclosure.

For example, the inlet/outlet junctures 151 need not be disposed one or each side wall 120. Rather, both may be disposed on a common side wall 120 or one or both may be disposed on the rear wall 110. Further, the inlet/outlet junctures 151 may be accessible from the interior or exterior wall surface or both.

In particular, features from one or more of the above-described embodiments may be selected to create alternative embodiments comprised of a sub-combination of features which may not be explicitly described above. In addition, features from one or more of the above-described embodiments may be selected and combined to create alternative embodiments comprised of a combination of features which may not be explicitly described above. Features suitable for such combinations and sub-combination will become readily apparent upon review of the present disclosure as a whole. The subject matter described herein and in the recited claims intends to cover and embrace all suitable changes in the technology.

According to a first broad aspect of the present disclosure, there is disclosed a precast monolithic concrete prefabricated, composite building construction module having a substantially planar rear wall, the rear wall having embedded therewithin a radiator pipe for circulating, within the rear wall, a fluid at a temperature that is different from an ambient temperature of the module.

A room formed of a plurality of such composite building construction modules, each lowered onto a floor surface in a vertical orientation and a roof element supported on the plurality of composite building construction modules, the radiator pipes of a plurality of the composite building construction modules being interconnected for supply of the fluid by a common circulating fluid source is also disclosed.

A building formed of a plurality of such composite building construction modules, each lowered onto a floor surface in a vertical orientation, the composite building construction modules defining a plurality of rooms interior of the building, some of which composite building construction modules defining external peripheral walls including free-standing composite building construction modules that are spaced apart to define gaps, and doors and windows fixed within the gaps, and at least one slab roof being supported by the composite building construction modules, the slab roof supported by the composite building construction modules of one storey and forming a floor surface of a next upper storey, the radiator pipes of a plurality of the composite building construction modules being interconnected for supply of the fluid by a common circulating fluid source is also disclosed.

Accordingly the specification and the embodiments disclosed therein are to be considered examples only, with a true scope and spirit of the disclosure being disclosed by the following numbered claims:

Claims

1. A precast monolithic concrete prefabricated, composite building construction module having a rear wall, the rear wall having first and second substantially planar exposed surfaces surrounding a unitary radiator pipe for circulating in a pattern extending substantially longitudinally and transversely throughout and within the rear wall, a fluid at a temperature that is different from an ambient temperature of the module, for radiating thermal energy related to a difference between the fluid temperature and the ambient temperature through the exposed first surface and the exposed second surface.

2. The composite building construction module according to claim 1, further comprising at least one substantially planar side wall integral with the rear wall, the at least one side wall terminating at one end at a corresponding end of the rear wall.

3. The composite building construction module according to claim 2, wherein the at least one side wall sufficiently supports the rear wall to cause the module to be free standing while substantially devoid of lateral support.

4. The composite building construction module according to claim 2, the rear wail having a length and the at least one side wall having a length and extending in a first direction substantially normally away from the rear wall sufficient to substantially enclose and define walls of a standard facility.

5. The composite building construction module according to claim 1, wherein the radiator pipe lies substantially entirely within the module.

6. The composite building construction module according to claim 1, wherein the radiator pipe is composed of plastic.

7. (canceled)

8. The composite building construction module according to claim 1, wherein the pattern is selected from a group consisting of an undulating pattern and at least one coil.

9. The composite building construction module according to claim 1, wherein respective first and second ends of the radiator pipe terminate at corresponding inlet/outlet junctions accessible from beyond the module.

10. The composite building construction module according to claim 9, the inlet/outlet junction for connection to an inlet/outlet junction of a different module.

11. The composite building construction module according to claim 9, the inlet/outlet junction for connection to a circulating fluid source.

12. The composite building construction module according to claim 11, wherein the circulating fluid source is selected from a group consisting of a solar water heater, an air conditioning unit, a refrigeration unit, a heat pump, a geothermal heat pump, an inline water heater, a hot water tank heated by electricity, natural gas and/or propane any any combination of these.

13. The composite building construction module according to claim 11, wherein the circulating fluid source and the module are connected through and separated by an element selected from a group consisting of a different module, a circulating pump and any combination of these.

14. The composite building construction module according to claim 9, the inlet/outlet junction for accepting an external fluid connection.

15. The composite building construction module according to claim 14, wherein the inlet/outlet junction is selected from a group consisting of a spliced connection, an externally threaded connection, an internally threaded connection, a tap connection, a hose connection and a valve collection.

16. The composite building construction module according to claim 9, wherein the inlet/outlet junction is accessible from one of the at least one side walls of the component.

17. (canceled)

18. (canceled)

19. (canceled)

20. (canceled)

21. (canceled)

22. The composite building construction module according to claim 1, wherein the module is formed by pouring concrete into a reusable U-shaped open steel mold.

23. (canceled)

24. The composite building construction module according to claim 1, further comprising a network of conduits embedded within at least one wall of the module, the network terminating in at least one junction box embedded within the at least one wall and accessible from at least one surface of the at least one wall by chipping away concrete between the junction box and the wall surface.

25. The composite building construction module according to claim 24, wherein the radiator pipe lies within a space defined by the network.

26. The composite building construction module according to claim 1, wherein a top surface of the walls of the module defines an inwardly extending channel sized to accept at least one electrical cable.

27. The composite building construction module according to claim 1, wherein the radiator pipe is embedded in one of the at least one side walls of the module.

28. (canceled)

29. (canceled)

30. (canceled)

31. (canceled)

32. (canceled)