Structural panel and modular building formed using the panel

Abstract

A structural panel includes perimeter rails and parallel joists having top and bottom surfaces lying in common parallel planes. Between the joists and the rails are diagonal planar bridge members extending obliquely in zigzag manner such that an end of one of the bridge members butts an opposed end of a next one of the bridge members at a side face of the joist. Planar top cover sheets bottom cover sheet are adhesively bonded to the top and bottom surfaces of the rail members, bridge members and joists. When used in a modular building, the floor has sufficient stiffness for the module to be transported from an assembly location in finished condition with all interior and exterior cladding attached and with the walls are topped by finished sandwich ceiling panels. The roof structure spanning the assembled modules is built on at the installation location.

1 . A structural panel comprising:
 a first pair of parallel perimeter rail members arranged to define first sides of the panel;   a second pair of parallel perimeter rail members arranged to define second sides of the panel at right angles to the first sides;   a plurality of parallel joists extending between the first pair of perimeter rail members and parallel to the second pair of perimeter rail members;   the rail members and the joists having top surfaces lying in a common top plane and bottom surfaces lying in a common bottom plane;   each one of the second pair of perimeter rail members and the joists therebetween being connected to a next adjacent one of the second pair of perimeter rail members and the joists therebetween by a plurality of diagonal planar bridge members;   each of the diagonal planar bridge members extending obliquely between said one and said next adjacent one with one end edge fastened to a side face said one and an opposed end edge fastened to a side face said next adjacent one;   and with the diagonal planar bridge members extending obliquely between said one and said next adjacent one being arranged in zigzag manner such that an end of one of the bridge members butts an opposed end of a next one of the bridge members at a side face;   a planar top cover sheet lying in said common top plane and adhesively bonded to said top surfaces of said rail members and said joists;   and a planar bottom cover sheet lying in said common bottom plane and adhesively bonded to said bottom surfaces of said rail members and said joists.   
   
   
       2 . The structural panel according to  claim 1  wherein the top cover sheet and the bottom cover sheet each comprise a layer of sheathing boards. 
   
   
       3 . The structural panel according to  claim 1  wherein the ends of the bridge members are adhesively bonded to the faces of the joists. 
   
   
       4 . The structural panel according to  claim 1  wherein the top sheet and the bottom sheet are adhesively bonded to top and bottom edges respectively of the bridge members. 
   
   
       5 . The structural panel according to  claim 1  wherein the butting ends of the bridge members on opposite faces of the joists are aligned. 
   
   
       6 . The structural panel according to  claim 1  wherein the bridge members span between the top and bottom cover sheets. 
   
   
       7 . The structural panel according to  claim 1  wherein the bridge members comprise wood sheets. 
   
   
       8 . The structural panel according to  claim 1  wherein the structural panel is longer in direction between the first pair so that the joists extend in the longitudinal direction. 
   
   
       9 . The structural panel according to  claim 1  wherein the rail members are of a common construction with the joists. 
   
   
       10 . The structural panel according to  claim 1  wherein there is provided a lifting assembly for lifting the panel comprising a plurality of mounting plates extending at right angles to the top cover sheet and fastened to the panel at spaced positions thereon with each plate having a captive nut carried thereon and providing an end of the nut exposed at the top cover sheet, the lifting assembly including a plurality of threaded rods each for fastening to a respective nut so as to extend therefrom at right angles outwardly form the top cover sheet. 
   
   
       11 . The structural panel according to  claim 10  wherein the lifting assembly includes a plurality of second mounting plates extending at right angles to the bottom cover sheet and fastened to the panel at spaced positions thereon with each second mounting plate having a captive nut carried thereon and providing an end of the nut exposed at the bottom cover sheet for receiving a threaded fastener attached thereto. 
   
   
       11 . The structural panel according to  claim 10  wherein the lifting assembly includes a plurality of second mounting plates extending at right angles to the bottom cover sheet and fastened to the panel at spaced positions thereon with each second mounting plate having a captive nut carried thereon and providing an end of the nut exposed at the bottom cover sheet for receiving a threaded fastener attached thereto. 
   
   
       12 . The structural panel according to  claim 11  wherein respective ones of the mounting plates and respective ones of the second mounting plates are clamped together through a component of the panel which extends at right angles to the top and bottom sheets so as to be fastened to the panel. 
   
   
       13 . The structural panel according to  claim 12  wherein there are four components to which the plates are attached each of which extends at right angles to the joists and connects between a joist and a respective one of the second rail members. 
   
   
       14 . The structural panel according to  claim 1  wherein the top and bottom sheets are formed from rectangular sheets having a longer axis and a shorter axis and are arranged with the longer axis at right angles to the joists. 
   
   
       15 . A modular building comprising:
 at least two separate modular base sections which are constructed so as to be separately transportable from a location of construction to a location of installation;   each modular base section including a floor structure and upstanding walls mounted on the floor structure;   the base sections being arranged to be connected so as to mate the walls to define a peripheral wall and interior walls of the modular building;   a roof to cover the peripheral wall with the modular base sections connected;   the floor structure of each modular base section comprising a structural panel according to  claim 1 .   
   
   
       16 . The modular building according to  claim 15  wherein the interior walls and the peripheral wall are finished with all electrical connections and plumbing installed; the interior walls and the peripheral wall are finished with all windows, doors, and interior coverings installed; and the peripheral wall is finished with all exterior coverings installed. 
   
   
       17 . The modular building according to  claim 15  wherein the roof is a separate construction from the modular base sections constructed at the installation location after connection of the modular base sections and includes trusses spanning the peripheral wall so as to bridge over at least two of the modular base sections. 
   
   
       18 . The modular building according to  claim 15  wherein each of the modular base sections includes ceiling panels covering an open top of the walls thereof such that the ceiling panels form a top cover during transportation of the modular base sections. 
   
   
       19 . The modular building according to  claim 18  wherein the ceiling panels are structural sandwich panels formed of top and bottom sheet material and a layer of foam therebetween and connected thereto.