QUICK CONSTRUCTION COMPONENT
The invention relates to a prefabricated construction component for wooden architectures comprising at least one panel-shaped portion (23) and at least one panel support component (212) attached to the panel, and made of a single piece of high density wood by means of a moulding or extrusion type production process, enabling a quick assembly particularly by means of a plurality of support components forming ribs constituting side strips (212) each connected to a lower crossbeam (213) and an upper crossbeam (221), the prefabricated component (2) constituting a wall being closed at least partially by the panel (23), the prefabricated component resting on its lower crossbeam, the upper crossbeam, supported by side strips, being at a height corresponding to a floor-to-ceiling height.
The field of the invention relates to architectures based on wooden structures. The invention relates more particularly to an improvement to the construction elements used for houses with wooden structures.
Houses with wooden structures, also called MOBs, offer many advantages such as a gain in construction time, a gain in insulation with respect to the space occupied and houses with wooden structures are also cheap and environmentally friendly. The construction of houses with wooden structures is based on different techniques which permit rapid assembly carried out for example by two people. However, the assembly remains relatively complicated and is generally carried out by professional tradesmen specialised in this field. Furthermore, even if the wood used for the construction is an ecological material, the manufacture of certain pre-fabricated elements in rough wood generates losses of raw material associated to high energy consumption, when the rough wood is machined. The pre-fabricated elements made of wood are for example beams, joists and cleats.
The purpose of this invention is to propose pre-fabricated elements, for example for the construction of houses with wooden structures, of which the manufacture permits raw materials and energy to be saved.
Another purpose is that the manufacture of all of the component pre-fabricated elements, for example of a house, is quicker than according to know manufacturing modes.
Another purpose is that the assembly of the pre-fabricated elements is simpler and quicker, compared to the assembly of the elements currently used.
These purposes are achieved by means of a pre-fabricated construction element for wooden architectures which comprise at least one portion forming a panel and at least one element forming a panel support that is attached to the panel, made from a single piece of pressed wood by a moulding or extrusion type manufacturing method, characterised in that a plurality of support elements form stiffeners which compose lateral cleats each joined to a lower rail and to an upper rail, wherein the pre-fabricated element which composes a wall is sealed at least partially by the panel, the pre-fabricated element rests on its lower rail, and the upper rail, supported by the lateral cleats, is positioned at a height which corresponds to the height of the ceiling.
According to another specific aspect, at least one protruding quick attachment hook is positioned on the external edge of one of the two lateral cleats and at least one slot to accommodate the quick attachment hook is located on the outside edge of the other lateral cleat.
According to another specific aspect, the outside edge of one of the two lateral cleats comprises a first surface that is “S” shaped to block the air, that is curved or is in the form of a broken line and the external edge of the other lateral cleat comprises a second surface that is “S” shaped to block the air, that is curved or is in the form of a broken line that is complementary to the first one, to form an assembly between the two surfaces.
According to another specific aspect, the sealing panel has an undulated or broken line profile.
According to another specific aspect, the panel comprises at least one stiffener positioned on an external face of the panel and which forms a support surface for an insulating wall panel.
According to another specific aspect, the pre-fabricated element comprises in the panel a stiffener which forms a window frame positioned around the window opening, wherein the frame comprises an upper rail and a lower rail that are attached to two lateral posts.
According to another specific aspect, the pre-fabricated element comprises in the panel at least one stiffener forming a first reinforcing cleat joining the upper rail of the frame to the upper rail of the pre-fabricated element and in that it comprises in the panel at least one stiffener forming a second reinforcing cleat joining the lower rail of the frame to the lower rail of the pre-fabricated element.
According to another specific aspect, the pre-fabricated element comprises in the panel a stiffener forming a door frame positioned around a door opening, wherein the frame comprises an upper rail joined to two lateral posts, wherein the panel further comprises at least one stiffener which forms a reinforcing cleat joining the upper rail of the frame to the upper rail of the pre-fabricated element, wherein the vertical posts are joined by their lower end to the lower rail of the pre-fabricated element.
Another purpose is to create a component element of the roof.
According to this purpose, the pre-fabricated element comprises two pre-fabricated component elements of a well each extended by an oblique panel defined by two incorporated lateral rafters, wherein the two oblique panels join at their summit, and the incorporated cleats and rafters are positioned on one face of their associated panel facing towards the interior or the exterior, to form a pre-fabricated component element of the roof.
Another purpose of the invention is to propose a construction method, for example for houses with wooden structures, for which the fabrication permits savings of raw materials and energy to be made.
Another purpose is that all of the pre-fabricated elements used in this construction method are manufactured more quickly than the elements used according to the known manufacturing methods.
Another purpose is that the assembly step of the pre-fabricated elements is simpler and quicker, compared to the assembly of the elements that are currently used.
These purposes are achieved by a construction method for walls or houses comprising the following steps:
-
- drying of the wood shavings into laminate boards,
- impregnated gluing,
- orientation of the laminates on the tool,
- compression of the pre-fabricated construction elements,
- baking of the pre-fabricated construction elements,
- assembly of the pre-fabricated elements to one another,
characterised in that the assembly step comprises:
-
- raising a first pre-fabricated element equipped with a quick attachment hook,
- pushing the first pre-fabricated element towards a second pre-fabricated element, with the hook of the first pre-fabricated element positioned opposite a slot for accommodating the second pre-fabricated element,
- locking the first pre-fabricated element onto the second, by placing the first pre-fabricated element in its stable position.
According to another specific aspect, the compression step comprises the formation of protruding stiffeners on the board forming a frame around an opening.
Another purpose of the invention is to propose an assembly of pre-fabricated elements that form at least part of a house with at least the pre-fabricated component elements of a wall, characterised in that the pre-fabricated wall elements are joined together to form at least one wall of a house, wherein the upper rails of the pre-fabricated elements form at least one horizontal support beam for an upper floor or a roof.
According to another specific aspect, the assembly comprises a lower floor on which rest the pre-fabricated wall elements, wherein the floor comprises pre-fabricated elements that are each made from a single piece of pressed wood by a moulding or extrusion type manufacturing method, wherein each pre-fabricated element that composes the floor comprises a panel joined to a plurality of support elements in the form of stiffeners forming incorporated joists of the same length as the panel and positioned in parallel to one another.
According to another specific aspect, the assembly comprises at least one roof comprising a plurality of component elements of the roof mounted adjacently by their rafters.
The invention, with its features and advantages, will be more clearly understood upon reading the description made in reference to the appended drawings in which:
The invention will now be described in relation to the figures mentioned above.
The wall element (1a) comprises two incorporated lateral cleats (11a), an incorporated upper rail (12a) and an incorporated lower rail (13a), of the same depth (P). The lateral cleats (11a) are joined at one end to the upper rail (12a) and at the other end to the lower rail (13a). The lateral cleats and the upper and lower rails of this wall element (1a) thus form a rectangular frame, closed on one face by a panel (10a). Non-restrictively, the panel is positioned on the external side (EXT) of the building or the house during the construction. The interior (INT) and exterior (EXT) of the house are shown on each side by a dotted line in
Non-restrictively, the support element is incorporated into a panel that forms surfaces with a long generating line that is parallel to one edge of the panel and that each have a determined thickness.
The manufacture of the pre-fabricated wall element (1a) shown in
This type of construction element advantageously permits pre-fabricated construction elements to be manufactured without loss, for architectures with wooden structures. Various forms may be made, for example with a decoration.
Furthermore, the resistance of recomposed wood materials, such as the OSB type for example, is known, and the dimensioning of the pre-fabricated elements may be optimised to resist determined stresses, again permitting material to be saved. According to the prior art, raw wood beams are in fact over-sized to include a significant safety margin. The example of the wall element (1a) shown in
In general, the support elements incorporated into the sealing panels have the advantage that the pre-fabricated elements are quicker to assemble. Pre-fabricated wall elements (1a, 1b) such as for example those shown in
Non-restrictively, when two elements, such as for example two wall elements, are joined in contact with one another on a flat surface, the junction surface has complementary connecting or sealing forms. Complementary metal connecting elements (7, 8) added to the edges of a pre-fabricated wall element are for example shown in
Consequently, two pre-fabricated construction elements associated to two metal attachment parts, as shown on the element of
These attachment elements (7, 8) are quick attachment devices which permit rapid fitting of the various construction elements. Non-restrictively, the metal quick attachment elements lock into place or the definitive attachment is then made by known attachment means such as nails, screws or any other known means. The attachment elements (7, 8) thus facilitate the installation of the walls or the roof while permitting the construction elements to be held together. Furthermore, the right angled junctions of the attachment elements (7, 8) make the structure more rigid.
Non-restrictively, as shown in
In general, the pre-fabricated elements according to the invention are made of recomposed wood, such as for example of an OSB type material. The construction of pre-fabricated construction elements is then carried out similarly to the manufacture of OSB type “process” panels. The manufacture of pre-fabricated construction elements according to the invention starts by the entry of the wood then the debarking of the wood. The wood is then cut into laminates that are dried by quick drying in barrels. The dried laminates are then glued by impregnation then oriented on a tool and shaped. Compression and baking complete the manufacturing process of the construction elements before the finished product is evacuated. Non-restrictively, the construction elements are shaped by extrusion or moulding.
The manufacturing process of the pre-fabricated construction elements according to the invention has the advantage of being much quicker than a manufacturing process of the prior art. Indeed, in the prior art, the support elements, such as the posts and rails, made of solid wood, required much a longer drying time for the solid wood, contrary to this invention. The loss of time in machining was even more consequent as the manufacture of simple OSB panels was also required in the prior art.
Furthermore, in the prior art, the machining of the support elements to the correct dimensions caused waste and therefore a loss of raw material, as opposed to this invention wherein the use of the raw material is maximised. Similarly, in the prior art, planning after drying of the rough wood then cutting to the correct dimensions also caused a loss of raw material, contrary to the manufacturing process of this invention.
Finally, the manufacturing process of the pre-fabricated construction elements of this invention is much simpler and quicker as the pre-fabricated elements are made in one piece, by moulding or extrusion. Thus advantageously, part of the assembly of the prior art, for example of panels with cleats, is avoided, which permits a saving of human resources. Moreover, errors during assembly and the associated losses are also avoided. Again, the invention permits an economical production in terms of energy and raw materials which is therefore more ecological.
The example of the wall element shown in
Another pre-fabricated one-piece element (3) that may form part of a wall of a house is shown in
An example of the assembly of several elements is shown in
According to one variant, shown in
According to one embodiment, shown in
It should be obvious to a person skilled in the art that the present invention permits embodiments in many other specific forms without this leaving the scope of application of the invention, as claimed. Consequently, the present embodiments should be considered as illustrations, which may be modified to suit the field defined by the attached claims, and the invention should not be restricted to the details provided above.
Claims
1. Pre-fabricated construction element for wooden architectures comprising at least one portion forming a panel and at least one element forming a panel support that is attached to the panel, made from a single piece of pressed wood by a moulding or extrusion type manufacturing method, characterised in that a plurality of support elements form stiffeners which compose lateral cleats each joined to a lower rail and to an upper rail, wherein the pre-fabricated element which composes a wall is sealed at least partially by the panel, the pre-fabricated element rests on its lower rail, and the upper rail, supported by the lateral cleats, is positioned at a height which corresponds to the height of the ceiling.
2. Pre-fabricated element according to claim 1, wherein at least one protruding quick attachment hook is positioned on the external edge of one of the two lateral cleats and at least one slot to accommodate the quick attachment hook is located on the outside edge of the other lateral cleat.
3. Pre-fabricated element according to claim 1, wherein the outside edge of one of the two lateral cleats comprises a first surface that is “S” shaped to block the air, that is curved or is in the form of a broken line and the external edge of the other lateral cleat comprises a second surface that is “S” shaped to block the air, that is curved or is in the form of a broken line that is complementary to the first one, to form an assembly between the two surfaces.
4. Pre-fabricated element according to claim 1, wherein the sealing panel has an undulated or broken line profile.
5. Pre-fabricated element according to claim 1, wherein the panel comprises at least one stiffener positioned on an external face of the panel and which forms a support surface for an insulating wall panel.
6. Pre-fabricated element according to claim 1, comprising in the panel a stiffener which forms a window frame positioned around a window opening, wherein the frame comprises an upper rail and a lower rail that are attached to two lateral posts.
7. Pre-fabricated element according to claim 6, comprising in the panel at least one stiffener forming a first reinforcing cleat joining the upper rail of the frame to the upper rail of the pre-fabricated element and further comprising in the panel at least one stiffener forming a second reinforcing cleat joining the lower rail of the frame to the lower rail of the pre-fabricated element.
8. Pre-fabricated element according to claim 1, comprising in the panel a stiffener forming a door frame positioned around a door opening, wherein the frame comprises an upper rail joined to two lateral posts, wherein the panel further comprises at least one stiffener which forms a reinforcing cleat joining the upper rail of the frame to the upper rail of the pre-fabricated element, wherein vertical posts are joined by their lower end to the lower rail of the pre-fabricated element.
9. Pre-fabricated element according to claim 1, comprises comprising two pre-fabricated component elements of a well each extended by an oblique panel defined by two incorporated lateral rafters, wherein the two oblique panels join at their summit, and the incorporated cleats and rafters are positioned on one face of their associated panel facing towards the interior or the exterior, to form a pre-fabricated component element of a roof.
10. Construction method for walls or houses comprising the following steps:
- drying of the wood shavings into laminate boards,
- impregnated gluing,
- orientation of the laminates on the tool,
- compression of the pre-fabricated construction elements,
- baking of the pre-fabricated construction elements,
- assembly of the pre-fabricated elements to one another,
- wherein the assembly step comprises:
- raising a first pre-fabricated element equipped with a quick attachment hook,
- pushing the first pre-fabricated element towards a second pre-fabricated element, with the hook of the first pre-fabricated element positioned opposite a slot for accommodating the second pre-fabricated element,
- locking the first pre-fabricated element onto the second, by placing the first pre-fabricated element in its stable position.
11. Construction method for walls or houses according to claim 10 wherein the compression step comprises the formation of protruding stiffeners on the board forming a frame around an opening.
12. Assembly of pre-fabricated elements that form at least part of a house with at least the pre-fabricated component elements of a wall according to claim 1, wherein the pre-fabricated wall elements are joined together to form at least one wall of a house, wherein the upper rails of the pre-fabricated elements form at least one horizontal support beam for an upper floor or a roof.
13. Assembly according to claim 12, wherein the assembly comprises a lower floor on which rest the pre-fabricated wall elements, wherein the floor comprises pre-fabricated elements that are each made from a single piece of pressed wood by a moulding or extrusion type manufacturing method, wherein each pre-fabricated element that composes the floor comprises a panel joined to a plurality of support elements in the form of stiffeners forming incorporated joists of the same length as the panel and positioned in parallel to one another.
14. Assembly according to claim 12, comprising at least one roof comprising a plurality of component elements of the roof according to claim 9, wherein the pre-fabricated component elements of the roof are mounted adjacently by their rafters.
Type: Application
Filed: Apr 25, 2007
Publication Date: Aug 20, 2009
Inventor: Luc Sauteraud (Mortemart)
Application Number: 12/298,906
International Classification: E04C 2/38 (20060101); E04B 1/38 (20060101); E04B 2/70 (20060101);