Modular frame system using light-gage metal in building construction

Abstract

Embodiments of the present invention provide a modular frame system for building construction using prefabricated frame components that can be assembled at the construction site easily and quickly. A number of connection mechanisms or joints are employed to connect the beams, columns, trusses, bases and the like. More specifically, they include connections for column to base, column to beam, truss/beam to column, truss to column, and truss to beam. In accordance with an aspect of the invention, a modular frame apparatus for building construction comprises a column; a plurality of prefabricated, modular structural components to be connected to the column; and a plurality of connecting mechanisms each configured and prefabricated to connect one or more of the plurality of modular structural components to the column in a modular manner to form a building module for a building.

1 . A modular frame apparatus for building construction, comprising:
 a column;   a plurality of prefabricated, modular structural components to be connected to the column; and   a plurality of connecting mechanisms each configured and prefabricated to connect one or more of the plurality of modular structural components to the column in a modular manner to form a building module for a building.   
   
   
       2 . The modular frame apparatus of  claim 1   wherein the modular structural components include a base;   wherein the connecting mechanisms include a column sleeve having an outer shape generally matching a shape of a hollow interior of the column and an outer size slightly smaller than a size of the hollow interior of the column to fit inside the column; a footing anchor fastener to fasten the column sleeve to the base; a height adjusting ring having a dimension generally matching the dimension of the hollow column and being disposed between the column and the base and being disposed around the column sleeve, the height adjusting ring having a height selected to adjust the height of the column relative to the base; and a column fastener to fasten the column to the column sleeve.   
   
   
       3 . The modular frame apparatus of  claim 2  wherein the column sleeve includes an integrally formed nut; and wherein the column fastener comprises a threaded bolt to threadingly engage the integrally formed nut to fasten the column to the column sleeve. 
   
   
       4 . The modular frame apparatus of  claim 1   wherein the column includes at least one slot in a column wall between an exterior and a hollow interior of the column;   wherein the modular structural components include a beam; and   wherein the connecting mechanisms include a column connecting member attached to the beam, the column connecting member having a longitudinal body extending across and received into the slot of the column, and a transverse flange connected to the longitudinal body and having a slanted surface facing inwardly toward the beam; and a wedge-shaped choke configured to be disposed between the slanted surface of the transverse flange and the column wall.   
   
   
       5 . The modular frame apparatus of  claim 4  wherein the wedge-shaped choke includes a slot to receive the longitudinal body of the column connecting member. 
   
   
       6 . The modular frame apparatus of  claim 1   wherein the column includes a plurality of openings;   wherein the modular structural components include a beam; and   wherein the connecting mechanisms include a pair of L-shaped beam holding bars attached to a hollow interior of the beam, the beam holding bars having holes matching the openings of the column; and a plurality of fasteners configured to fasten the beam holding bars to the column via the holes of the beam holding bars and the holes on the column.   
   
   
       7 . The modular frame apparatus of  claim 6  wherein the beam holding bars are disposed slightly inward from an end of the beam facing the column. 
   
   
       8 . The modular frame apparatus of  claim 1   wherein the modular structural components include a beam;   wherein the connecting mechanisms include a tongue-in-groove connection; and   wherein the column includes one part of the tongue-in-groove connection and the beam includes another part of the tongue-in-groove connection.   
   
   
       9 . The modular frame apparatus of  claim 1   wherein the column is a lower column;   wherein the modular structural components include an upper column to be disposed above the lower column; and   wherein the connecting mechanisms include a transitional column sleeve having a shape generally matching shapes of the upper and lower columns and having a size slightly smaller than sizes of the upper and lower columns to fit inside hollow interiors of the upper and lower columns; and fasteners to fasten at least one of the upper and lower columns to the transitional column sleeve.   
   
   
       10 . The modular frame apparatus of  claim 9  wherein the column transitional sleeve includes integrally formed nuts to be threadingly connected by the fasteners to fasten the column transitional sleeve to at least one of the upper and lower columns. 
   
   
       11 . The modular frame apparatus of  claim 9  wherein the column transitional sleeve includes at least one slot matching at least one slot of one of the upper and lower columns. 
   
   
       12 . The modular frame apparatus of  claim 9  wherein the column transitional sleeve includes a plurality of holes matching openings in at least one of the upper and lower columns. 
   
   
       13 . The modular frame apparatus of  claim 1   wherein the modular structural components include a truss or a beam;   wherein the connecting mechanisms include a holder having a holder base connected to the column and a pair of spaced holder supports extending from the holder base to receive the truss or beam therebetween, the pair of spaced holder supports each including an aperture for a fastener to pass therethrough to fasten the truss or beam to the pair of spaced holder supports.   
   
   
       14 . The modular frame apparatus of  claim 13  wherein the column includes a column cap having a plurality of holes for connecting the holder base of the holder to the column cap via any one of the holes at selected location and orientation. 
   
   
       15 . The modular frame apparatus of  claim 1   wherein the column includes at least one slot in a column wall between an exterior and a hollow interior of the column;   wherein the modular structural components include a truss; and   wherein the connecting mechanisms include a column connecting member attached to the truss, the column connecting member having a longitudinal body extending across and received into the slot of the column, and a transverse flange connected to the longitudinal body and having a slanted surface facing inwardly toward the truss; and a wedge-shaped choke configured to be disposed between the slanted surface of the transverse flange and the column wall.   
   
   
       16 . The modular frame apparatus of  claim 1   wherein the column includes at least one slot in a column wall between an exterior and a hollow interior of the column;   wherein the modular structural components include a truss; and   wherein the connecting mechanisms include a column connecting member attached to the truss, the column connecting member having a longitudinal body extending across and received into the slot of the column, a distal transverse flange connected to the longitudinal body to be disposed at an outer surface of the column wall, and a proximal transverse flange connected to the longitudinal body and having a slanted surface facing outwardly toward the distal transverse flange to be disposed adjacent an inner surface of the column wall; and a wedge-shaped choke configured to be disposed between the slanted surface of the proximal transverse flange and the inner surface of the column wall.   
   
   
       17 . The modular frame apparatus of  claim 1   wherein the modular structural components include a truss; and   wherein the connecting mechanisms include a beam connected to the column, the beam having a plurality of key slots; and a plurality of protrusions at an end of the truss to be received into the key slots of the beam.   
   
   
       18 . The modular frame apparatus of  claim 1   wherein the modular structural components include a truss; and   wherein the connecting mechanisms include a beam connected to the column, a holder base mounted to the beam, and a pair of spaced holder supports extending from the holder base to receive the truss therebetween, the pair of spaced holder supports each including an aperture for a fastener to pass therethrough to fasten the truss to the pair of spaced holder supports.   
   
   
       19 . The modular frame apparatus of  claim 1  wherein the column is formed by two column segments connected by a column extension sleeve. 
   
   
       20 . The modular frame apparatus of  claim 1   wherein the modular structural components include a beam; and   wherein the beam is formed by two beam segments connected by a beam extension sleeve.   
   
   
       21 . A system for coupling a column to a base comprising:
 a column sleeve having an outer shape generally matching a shape of a hollow interior of the column and an outer size slightly smaller than a size of the hollow interior of the column to fit inside the column;   a footing anchor fastener to fasten the column sleeve to the base;   a height adjusting ring having a dimension generally matching the dimension of the hollow column and being disposed between the column and the base and being disposed around the column sleeve, the height adjusting ring having a height selected to adjust the height of the column relative to the base; and a column fastener to fasten the column to the column sleeve.   
   
   
       22 . The system of  claim 21  wherein the column sleeve includes an integrally formed nut; and wherein the column fastener comprises a threaded bolt to threadingly engage the integrally formed nut to fasten the column to the column sleeve. 
   
   
       23 . A system for coupling a column to a beam comprising:
 a column connecting member coupled to the beam, said column connecting member having a longitudinal body extending across and received into a slot of the column, and a transverse flange connected to the longitudinal body and having a slanted surface facing inwardly toward the beam; and   a wedge-shaped choke configured to be disposed between the slanted surface of the transverse flange and the column wall.   
   
   
       24 . The system of  claim 23  wherein the wedge-shaped choke includes a slot to receive the longitudinal body of the column connecting member.