Prefabricated Module Used for Living Accommodations
The invention relates to a pre-fabricated module for living accommodation, comprising: a base; two left and right side façades; a front façade comprising a entrance door; a rear window façade; and a roof element. wherein the base, the façades and the roof element are all made of a structure comprising a layer of projected phenolic resin with embedded electrical ducting. In a particular mode of embodiment, the pre-fabricated module comprises a utility shaft having its own access door on the front face and passing through said module from bottom to top, enabling the interconnection with two other modules respectively arranged beneath and above said pre-fabricated module.
This application is a Continuation of PCT Application no. PCT/EP2012/001148, which was filed on Mar. 14, 2012, and which is herein incorporated by reference in its entirety.
TECHNICAL FIELDThe present invention relates to the field of construction and more specifically a prefabricated module for residential use which is particularly light and economical.
BACKGROUNDThe demographic development faced by all Western societies as well as developping countries gives a particularly critical focus to the issue of providing a House to everybody.
It is therefore extremely important to meet the growing needs in this field and to achieve technical solutions being easy to carry out and economic.
The technique of prefabricated construction provides a first solution to this problem since buildings for residential use can be fastly constructed.
However, such technique requires highly specialized skill to be used, thus making its use quite confidential. It would be necessary to be able to develop more this technique so that everybody is given the opportunity to use it for the purpose of solving the problem of Housing.
It is therefore highly desirable to achieve a fully prefabricated housing unit, allowing multiple configurations, which would simultaneously provide comfort, lightness, durability and, of course, economy in its use.
Such a wish shows to be critical even out of the crucial context—even dramatic in some circumstances—of the housing problem known by nowadays societies. Indeed, when considering for instance the field of tourism that is being developped in many regions and even in developping countries, it can be seen that even in such lighter context, it is also desirable to have a light, functional and durable solution to provide cost-effective solutions to public housing temporary, and particularly small and economic hotel architectures can be easily deployed on site with minimal impact on the natural environment.
Such are the problems that are solved by the present invention.
SUMMARYIt is a first object of the present invention to achieve a prefabricated module, especially for residential use or even hotel, which is particularly functional, durable and economical to install.
It is another object of the present invention to achieve a prefabricated module that can be easily deployed by combination of small functional modules, both in the vertical and in the horizontal directions, thus facilitating the deployens the different modules for the purpose of arranging a more complex residential structure or even an hotel.
It is still another object of the present invention to achieve a prefabricated module incorporating all the modern features and facilities to ensure the comfort of an occupant, and at a particularly low cost.
The invention achieves these objects by means of a prefabricated module for residential use having a base and walls which are made exclusively by means of a layer of phenolic resin proposed embedding electrical conduit.
In a particular embodiment, the prefabricated module further comprises a service shaft or conduit having its own access door opening outside, the service shaft crossing the whole module from the bottom to the top and enabling the interconnection with two other modules, respectively disposed on and under said prefabricated module
In a particular embodiment, the base comprises two plates, respectively bottom and top which are separated by re-splits and further comprising a cutout for the passage of the service shaft. In the top plate composing the base, there is embedded a shower tray top plate within the thickness of the phenolic resin composing the floor of the module.
In one particular embodiment, the service shaft has two side portions, respectively right and left, and a rear wall. An inner boundary element also composed of phenolic material, is used for achieving a delimitation within the inner volume of the service shaft of two subvolumes, respectively dedicated to the water flows and to the high/low voltage electrical distribution system.
In a particular embodiment, the inner element has a profile showing three sections, respectively horizontal, vertical and horizontal section for the purpose accomodating a heating/air conditioning unit.
In a particular embodiment, the syphon of the shower is directly offset within the internal volume of the service shaft for the purpose of facilitating visiting and maintenance from the outside access door of the service shaft.
Preferably the module is associated with a frame having a base composed of modules of the type “HN” and having four posts having a “L” profile, each post comprising at the top one bracket for supporting the base of a upper prefabricated module, thus allowing the stacking of different prefabricated modules.
The frame can be made of metal or extruded polyester resin.
In a particular embodiment, the facades comprise, within their internal structure, a decorative photographic layer.
Other features, objects and advantages of the invention will become apparent upon reading the following description and drawings below, given by way of non-limiting examples. In the accompanying drawings:
There is now described one particular embodiment of a highly functional, lightweight and inexpensive to manufacture and maintain prefabricated, module.
The following description will be particularly suited to the production of a prefabricated module for tourism, offering its occupants all the modern features and comfort that one may expect from a modern hotel and which, moreover, has exceptional durability even in very difficult exploitation conditions.
Clearly, one may adapt the description of the prefabricated module to the achievement of an T1 type apartment or a larger apartment by combining different modules, as described below, so as to achieve more complex architectural structures.
The prefabricated module which is described below has a particularly economic manufacturing process and shows a light structure.
For this purpose, it is exclusively made from seven components, described below, all resulting from the same manufacturing process and, preferably, made exclusively from panels composed of phenolic polyester resin.
Such material is known in the manufacturing process of ships and aircraft since it allows the manufacturing of thin and resistant shells.
The inventors have discovered that it is possible to spray much thicker layers of phenolic resin for the purpose of embedding, within the same panel, electrical conduit and thus achieve, in a single manufacturing a complete prefabricated façade being particularly light (despite the thickness of the layer of phenolic resin), economic and easy to implement.
There is one proposed a new structure for a prefabricated module which is exclusively realized from such material and that then leads to the possibility of producing a lightweight, economical unit, particularly resistant and durable.
It is seen that the structure comprises a succession of elementary layers so as to realize a lightweight and durable wall or panel. Starting from the inside of the wall to the outside, there is a first layer 91 of fibreglass, such as of the mat Gel Coat type which is well-known to the skilled man versed in the construction of ships and aircrafts, and an aluminium structure net 92 which, and this is particularly advantageous, will be the only metallic structural element of the panel, then a sprayed resin having a high thickness, up to 10 cm. At the top of the panel, one arranges a further aluminium structure net 94, then covered with one or more layers of Gelcoat mat for completing the final aspect of the panel.
Phénolyque resin used in this particular embodiment provides a significant advantage in that its mechanical characteristics does not diminish when exposed to high temperatures, such as in case of fire within the module.
The resulting wall shows outstanding features, particularly in terms of sound and thermal insulation, but also in terms of fire behavior. One may nonetheless optionally combines the wall with an additional fireproof panel, such as a M2 panel being surfaced and laminated or similar, which will provide additional fire protection, which will improve the already existing fire protection resulting from the use of the phenolic resin layer 93.
As this is shown in
One can furthermore decorate the outside panel wall surface with an additional layer allowing photograph inclusion of a material type wood, marble, stone etc. . . . .
As an alternative, and in a second embodiment (not shown in the figure), the projected foam resin can be replaced by an expanding foam under vacuum injected between two layers of resin, and which is glued. One can also obtain, when using a phenol based foam with or any material showing equivalent mechanical and fire protection characteristics, a panel having high mechanical strength and complying with the European legislation requirements, providing good fire resistance and which do not release toxic fumes which might be harmful to the health of the occupants of the module.
These panels can be made in many ways, hand made or by means of industrial production, according to choice.
In a third embodiment, each panel is produced with gelcoat (2 sides, inner skin and outer skin), which receive between them, expanded foam with ceramic fire resistance sheet increasing the fire resistance level. Within the expanded foam there is embedded a structure of extruded resin, having double volume serving for technical passages (low voltage or high voltage) distributing technical services in the composed module, forming perimeter belt for the ceiling, the side walls and the floor, in high or low level in module height, connecting the utility or service shaft with all parts of the finished module.
Different assembling inserts made of extruded resin are disposed inside of the panels in order to permit screwing when mounting or dismounting the housing module on different operating sites. These panels are made airtight by means of gel coat resin, also completing the aesthetic finish. The expanding foam can be made on the basis of Phenol, but can also be replaced by panels made up of alveolar membranes in resin, or the polyurethane foam injected by vacuum suction.
More specifically, the method described below can be used for producing a panel of this type which will advantageously be used for partitioning the habitation module.
For this purpose, there is arranged a mold defining the panel on the bottom and sides (like a drawer), in which one disposes gel-coat finishing façade and a ceramic fire resistance sheet, with pultrusion resin structure, receiving all technical passages, with all spare parts assembly items such as resin inserts for screwing and or reinforcement. On this arrangement a plastic membrane is set defining a volume having an inlet for injecting the expanding foam and an outlet for connection to a suction device. In this way, by plugging the vacuum suction, one can inject under vacuum the expanding foam that fills the interstices and the internal volume of the panel. One then completes the whole by a gelcoat membrane ensuring the hermetic character of the panel and completing the aesthetic finish.
It is now described the use of such a panel or element for the achievement of a prefabricated module having, such as illustrated in
As seen in
It should be noted that, in a particular embodiment, the shower can be covered with a cover so as to restore the flatness of the ground for the case where the shower embedded space is not required, for instance when the occupant of prefabricated module would not wish to use the corresponding surface for a wash room.
As can also be seen, and will be described in more detail below, the upper and lower plates have a cutout disposed on the side of the front door for receiving a vertical service shaft extending from bottom to the top of the prefabricated module, and which will be described in more detail below. Generally speaking, all water and electricity conduits lead to the volume delimited by such cut, as illustrated with the drain tube 18 of the shower, so that all equipments and technical devices can take place within the single service shaft of the prefabricated module. In a particular embodiment, even the shower drain is arranged within the volume delimited by the service shaft so as to allow maintenance operations directly from outside the module.
The panel 20 has some reliefs—such as the re-split wall 22—can be used for partitioning and delimiting, as appropriate, spaces on the wall and further includes in its lower part a console 23 having the profile of a shoe for being inserted between the lower plate 11 and upper plate 12 of the base member of
The left side wall of the prefabricated module can embed prefabricated furniture, such as a sink 25, a wall bed 26, and various connectors (telephone, electricity, Ethernet) and switches—for example 27 and 28—and electrical sockets 29.
As was mentioned previously, electrical sheathing distribution of small high-current power is embedded within the phenolic resin, thus achieving functionality, lightness and safety.
As noted, the roof element 40 is also based on a sandwich structure consisting of sprayed phenolic resin so that the weight of the roof is particularly light.
It is described with reference to
The service shaft 70 consists of two vertical plates 71 and 72, extending from the bottom to the top of the prefabricated module and having two interior volumes delimited by means of an intermediate element comprising three plate sections 73, 74 and 75 respectively vertical, horizontal and vertical.
It follows that the sheath has two technical areas or volumes, the first volume (left) is particularly slender at the top and wide at its bottom part. Instead, the second volume (right) is particularly slender in its lower and wider in its upper part.
The left volume is assigned to the water drainage—cold water, wastewater,—while the right volume is dedicated exclusively to high and low voltage.
It should be noted that walls 71-75 of the service shaft 70 are also made up thanks to the sandwich structure described above made of phenolic resin illustrated in
As seen in
In a particular embodiment, the technical shaft includes, within its “drainage” volume, a water inlet hose 77 comprising in the lower and upper parts, connectors allowiung the connexion of the technical shafts of different modules, and a stopcock 87. One also finds the wastewater discharges 78 (connected to a toilet advantageously fixed with low costs on the other side of the rear wall of the service shaft) and sewage 79 and, very advantageously, the trap 86 the shower tray 15 which is thus deported within the volume of the service shaft thanks to a large diameter pipe allowing the water flow from the shower tray down to the trap. It should be noted that the rear wall of the technique used to define the habitation volume inside the prefabricated cabin module and also used to support a toilet and communicating directly with the service shaft.
The right volume has, meanwhile, a heating/air conditioning 76 taking place on the horizontal section 74 of the intermediate member 73-74-75. On the other side of the wall 71, all the control elements of the electrical components are located, including a main circuit breaker, branch circuit breakers of 82 various switches 83 (central lighting) and a convector heating and air conditioning running 85 in cooperation with the air conditioning unit/heater 76. The various organs are placed directly at the entrance to the interior of the prefabricated module, and thus communicate directly with the service shaft since it is the same partition or wall 71 which ensures the delimitation.
As can be seen, this is an arrangement is extremely convenient since the technique provides sheath along the boundary of the interior (via the wall 71 and rear wall), the delineation of two volumes completely disjoint respectively assigned to the liquid flows and electricity wires.
For this purpose, there is arranged a base consisting of four metallic “HN” type elements composing a base 100 on which one can position the prefabricated module. In a particular embodiment, two metallic elements—a length 101 and a width 102—are welded during the manufacturing process in factory and arranged for allowing bolting the two halves of the base on the installation site. The four corners of the base 100, one arranges four posts 120 with a “L” profile having in their upper portion a bracket 130 for supporting another structure identical to the one illustrated in
In a particular embodiment, the “L” profile posts are arranged to provide the shortest part of the “L” to the front and rear faces of the prefabricated module so as to facilitate release of a lower module once it is in place in a vertical structure.
In a particular embodiment, the frame 100 is made of extruded polyester resin to further reduce the weight of the structure.
As seen, the prefabricated module provides easy regarding the deployment “vertical” and can, at will, replace a module with another as needed. One can even imagine the organization of a complex in which they come, as necessary, come position specific modules (eg providing services for people with disabilities) and which could use the operator the complex.
The “horizontal” deployment of prefabricated modules according to the invention is also extremely easy as simply position as modules next to each other to have either individual units or more spacious apartments with different parts such as we see illustrated in
In a particular embodiment, the facade/walls 20 and 30 may be equipped with a door allowing communication between two modules located one beside the other and thus expanding the surface offered to occupants of the modules.
The module allows great flexibility, allowing the occupants to enlarge the surface according to the needs and resources.
It is seen in particular in
The structure is easily disassembled and transported, each panel being very light and being embedded with all technical facilities of the housing unit, in particular the washroom. Thus, by disassembling the front façade comprising the entrance door, one can completely change the electrical system, including the air conditioning system. The module will be easily removable and can be reinstalled as desired by various successive locations.
They can very easily be using in the hospitality industry, allowing their installation and removal as needed.
Claims
1. A pre-fabricated module for living accommodation, comprising:
- a base;
- two left and right side façades;
- a front façade (50) comprising a entrance door;
- a rear window façade;
- to and a roof element;
- wherein the base, the façades and the roof element are all made of a structure comprising a layer of projected phenolic resin with embedded electrical ducting,
- wherein the pre-fabricated module further comprises
- a utility shaft having its own access door on the front face and passing through said module from bottom to top, enabling the interconnection with two other modules respectively arranged beneath and above said pre-fabricated module.
2. The pre-fabricated module for living accommodation according to claim 1 further comprising a technical shaft, fitted with its own access door on the front side and extending from the bottom to the top of said module, said technical shaft allowing the interconnection with two other modules respectively arranged below and above said prefabricated module.
3. The pre-fabricated module for living accommodation according to claim 1 wherein said base comprises a lower plate and an upper plate separated by two re-splits walls et further comprising a cutout for the passage of said technical shaft, said top plate further comprising a shower tray embedded within the thickness of the projected phenolic resin.
4. The pre-fabricated module for living accommodation according to claim 2 wherein said technical shaft comprise a right side wall, a rear side and a left side wall, and an interior delimitation element allowing partitioning of said technical shafts in a first and a second volume being respectively dedicated to the flowing of liquids and to the high/low voltage supply wires.
5. The pre-fabricated module for living accommodation according to claim 4 wherein said delimitation element further comprises three sections respectively vertical, horizontal and vertical which are so adapted for accommodating a heating/air condition system on said horizontal section.
6. The pre-fabricated module for living accommodation according to claim 5 wherein said first volume comprises a siphon for the shower being deported within said technical shaft so as to facilitate plumbing maintenance operations.
7. The pre-fabricated module for living accommodation according to claim 1 further comprising a frame comprising a base composed of modules of the type “HN” and having four posts having a “L” profile, each post comprising at the top one bracket for supporting the base of an another upper prefabricated module.
8. The pre-fabricated module for living accommodation according to claim 7 wherein said frame is metallic.
9. The pre-fabricated module for living accommodation according to claim 7 wherein said frame is realized in extruded polyester resin.
10. The pre-fabricated module for living accommodation according to claim 1 wherein one façade comprises, within its internal structure, a decorative photographic layer.
11. A pre-fabricated module for living accommodation comprising: the base, the facades and the roof element having all a structure comprising a layer of resin wherein is embedded electrical sheath.
- a base forming the floor of said module and which further embodies a washroom floor comprising a shower tray being embedded within said floor;
- two left and right side façades, one façade being constitutive of a first vertical wall of said washroom, and having washroom accessories embedded therein;
- a front façade comprising a entrance door as well as a technical shaft, said front façade forming a second vertical wall for said washroom;
- a rear window façade;
- a roof element or covering embodying the ceiling of said module and said washroom with its shower;
12. The module according to claim 11 wherein said base, the facades and the roof element or cover comprises a panel having a structure being composed, from inner to outside:
- a first layer of glassfiber;
- a metallic frame, for instance in aluminium
- a thickness of projected resin;
- a structural metallic frame, for instance aluminium;
- a second layer of glass fiber for completing the aesthetical aspect of the panel.
13. The module according to claim 12 wherein said projected resin is a phenolic resin having a thickness equal to about 10 centimeters.
14. The module according to claim 11 wherein said base, the facades and the room element are all realized with panels based on injected expanded foam.
15. The module according to claim 14 wherein said injected expanded foam is made with phenol.
16. The module according to claim 1, wherein it is adapted for allowing combination with another module so as to achieve a two rooms flat.
17. A process for realizing a panel for a facade of a module for living accommodation according to claim 14, further comprising the steps:
- providing a mould for delimitation of the floor and the sides the panel to be realized;
- providing gelcoat on each side of said mould;
- providing a ceramic and elements made of extruded resin for the passage of electric wires;
- providing a plastic membrane defining a volume having an inlet for injecting the expanding foam and an outlet for connection to a suction device;
- injection under partial vacuum of said expanded foam;
- providing a gelcoat membrane achieving hermetic character of the panel and completing the aesthetic aspect.
18. The process according to claim 15 wherein said expanded foam is realized from phenel or polyurethane foam that is injected under vacuum.
Type: Application
Filed: Sep 13, 2013
Publication Date: Jan 16, 2014
Inventor: Alain Marc Yves Deverini (Monaco)
Application Number: 14/026,559
International Classification: E04H 1/02 (20060101);