U.S. patent application number 10/839666 was filed with the patent office on 2005-11-10 for modular building structure.
Invention is credited to Bedell, Rick, Moss, Paul Neal.
Application Number | 20050247024 10/839666 |
Document ID | / |
Family ID | 35238185 |
Filed Date | 2005-11-10 |
United States Patent
Application |
20050247024 |
Kind Code |
A1 |
Bedell, Rick ; et
al. |
November 10, 2005 |
Modular building structure
Abstract
Disclosed herein is a modular building structure. The structure
includes a modular building roof structure comprising the roof
structure which includes a plurality of truss structures each
having a top and a bottom and a pair of deck layers attached to and
for transversely spanning the tops of the truss structures. The
roof structure also includes an acoustical ceiling suspended along
the bottoms of the truss structures. The building structure also
includes a modular building floor structure which comprises a deck
structure including an upper deck pan and a lower deck pan disposed
opposite and adjacent each other to create a plurality of spaced
apart support channels. In a preferred embodiment, the deck
structure is oriented transverse to the support beams. The floor
structure further includes a plurality of support beams for
supporting the deck structure. Significantly, the deck and the
acoustical ceiling define a return air plenum that provides for
proper venting, distribution and circulation of air, including
introduction of fresh air, throughout the modular structure.
Advantageously, no separate ductwork or duct system is required
with the use of the air plenum. Preferably, the structure is
substantially non-combustible and mold-resistant.
Inventors: |
Bedell, Rick; (Bristol,
IN) ; Moss, Paul Neal; (Constantine, MI) |
Correspondence
Address: |
WHYTE HIRSCHBOECK DUDEK S C
555 EAST WELLS STREET
SUITE 1900
MILWAUKEE
WI
53202
US
|
Family ID: |
35238185 |
Appl. No.: |
10/839666 |
Filed: |
May 5, 2004 |
Current U.S.
Class: |
52/790.1 |
Current CPC
Class: |
E04B 5/10 20130101; E04B
1/3483 20130101; E04B 5/04 20130101 |
Class at
Publication: |
052/790.1 |
International
Class: |
E04B 001/00; E04B
005/00; E04B 007/00; E04C 002/34 |
Claims
What is claimed is:
1. A modular building roof structure in combination with an
acoustical ceiling, the combination comprising: a modular building
roof structure comprising: a plurality of truss structures each
having a top and a bottom; a pair of deck layers attached to and
for transversely spanning the tops of the truss structures; and an
acoustical ceiling suspended along the bottoms of the truss
structures; wherein the deck and the acoustical ceiling define a
return air plenum.
2. The combination of claim 1 wherein the trusses further comprise
a plurality of longitudinally disposed supporting beams connected
in overlapping relationship to a plurality of tension and
compression members such that the trusses form a longitudinal, open
web truss structure.
3. The combination of claim 1 wherein the pair of deck layers is
roll-formed.
4. The combination of claim 1 wherein the pair of deck layers is
corrugated.
5. The combination of claim 1 wherein the pair of deck layers is
constructed of steel.
6. The combination of claim 1 wherein the modular building roof
structure is at least one of substantially non-combustible and
substantially mold-resistant.
7. The combination of claim 1 further wherein at least one of the
plurality of longitudinal, open web trusses, the plurality of
tubular columns, and the roll-formed deck comprise steel.
8. A modular building floor structure comprising: a deck structure
including an upper deck pan and a lower deck pan disposed opposite
and adjacent to each other to create a plurality of spaced apart
support channels; and a plurality of support beams for supporting
the deck structure; wherein the deck structure is oriented
transverse to the support beams.
9. The modular building floor structure of claim 8 further
comprising a decking surface laid over the pair of deck pans.
10. The modular building floor structure of claim 9 wherein the
decking surface includes plywood and wherein the plywood is
supported at least in part by the support channels.
11. The modular building floor structure of claim 8 wherein the
decking surface includes cement board and wherein the cement board
is supported at least in part by the spaced apart support
channels.
12. The modular building floor structure of claim 8 wherein the
decking surface includes poured concrete and wherein the concrete
is supported at least in part by the support channels.
13. The modular building floor structure of claim 8 wherein at
least one of the upper and lower deck pans is corrugated.
14. The modular building floor structure of claim 8 wherein the
deck structure is capable of supporting a greater load than each of
one of the pair of deck pans individually.
15. The modular building floor structure of claim 8 wherein the
deck structure has a combined deflection level that is less than an
individual deflection level for each of the deck pans individually
for a given load.
16. The modular building floor structure of claim 8 wherein the
support members comprise at least one I-beam.
17. The modular building floor structure of claim 16 wherein the
support members comprise two I-beams.
18. The modular building floor structure of claim 8 wherein the
plurality of main support beams are spaced apart in intervals that
are in a range of about 12 to about 14 feet.
19. A modular building structure comprising: a modular building
roof structure in combination with a suspended acoustical ceiling
system, the combination comprising: a modular building roof
structure comprising: a plurality of truss structures each having a
top and a bottom; a pair of deck layers attached to and for
transversely spanning the tops of the truss structures; and an
acoustical ceiling suspended along the bottoms of the truss
structures; and a modular building floor structure comprising: a
deck structure including an upper deck pan and a lower deck pan
disposed opposite and adjacent each other to create a plurality of
spaced apart support channels; and a plurality of support beams for
supporting the deck structure; wherein the deck and the acoustical
ceiling define a return air plenum; and wherein the deck structure
is oriented transverse to the support beams.
20. The modular building structure of claim 19 wherein the upper
deck pan and the lower deck pan are separated to create a plurality
of deck gaps, and further including a plurality of spacers inserted
into the plurality of deck gaps.
21. The modular building structure of claim 19 further including
inserting support materials into the plurality of spaced apart
support channels for increasing the support strength of the deck
structure.
22. The modular building structure of claim 19 wherein each modular
building has a lateral load bearing characteristic, and that when a
plurality of the modular buildings are placed laterally together to
create a modular building group having a total lateral load bearing
characteristic, the total lateral load bearing characteristic is
additive from the individual modular building lateral load bearing
characteristics.
23. The modular building structure of claim 19 wherein the pair of
deck layers are separated to create a plurality of deck gaps, and
further including a plurality of spacers inserted into the
plurality of deck gaps.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to modular building
systems, and more particularly to modular building roof and floor
structures.
[0002] Modularly constructed building structures are advantageous
in that they provide shelter from the elements in which a variety
of activities can be housed, and are relatively easily transported
from one locale to another. Moreover, such structures can typically
be assembled in stackable sections, or sections placed side-by-side
(i.e., the sections are positioned adjacent each other), right on
site after being transported. Modular building structures can be
used for production of single and multi-unit or multi-family homes,
as well as apartments, condominiums, classrooms, general offices,
medical facilities, commercial buildings and the like.
[0003] Many modular building structures are custom designed.
However, building structures can also be designed according to
standard or pre-fabricated building templates as well. Today's
modular building structures are computer-engineered to meet
national building codes. They can be precisely engineered for
increased structural durability. High quality can be maintained by
inspection during construction process. In one construction
example, a modular building structure is delivered to a desired
site, after which individual modular structures or "modules" are
assembled into an overall modular building structure.
[0004] In general, the metrics of building construction costs break
out on a per square foot basis. It is a continuous goal to reduce
the construction costs of the modular structures. To this end, it
would be desirable to provide a modular building structure that,
while meeting all applicable building codes and other standards, is
simpler to construct than known modular building structures. For
example, a building structure comprising fewer pieces, parts or
other components in its construction is desirable. Similarly,
material selection for such modular building structures is key, in
that the material type and placement can result in a building
structure of having a greater useful life and durability.
[0005] It would also be desirable to use stronger and more durable
modules or substructures in making the overall modular building
structure. This can lead to a decrease in the number of supports or
braces in a given area, thereby reducing modular building structure
costs on a square foot basis. Advantageously, the mating of various
components can provide increased strength, which, in conjunction
with the reduction in the number of support structures, reduces
overall modular weight, in addition to construction and
transportation costs.
[0006] Further, in the modular building structure industry, there
are increasing requirements aimed at improving the structure
resistance to mold and combustion. Accordingly, it would be
desirable to provide a modular building structure that increases
the used of stainless steel materials in order to achieve these
desired ends.
BRIEF SUMMARY OF THE INVENTION
[0007] An inventive modular building structure is disclosed herein.
In one embodiment, a modular building roof structure in combination
with an acoustical ceiling is disclosed, the combination comprising
a modular building roof structure comprising a plurality of truss
structures each having a top and a bottom; a pair of deck layers
attached to and for transversely spanning the tops of the truss
structures; and an acoustical ceiling suspended along the bottoms
of the truss structures; wherein the deck and the acoustical
ceiling define a return air plenum.
[0008] In another embodiment, a modular building floor structure is
disclosed comprising a deck structure including an upper deck pan
and a lower deck pan disposed opposite and adjacent each other to
create a plurality of spaced apart support channels; and a
plurality of support beams for supporting the deck structure. In a
preferred embodiment, the deck structure is oriented transverse to
the support beams.
[0009] And in another embodiment, a modular building structure is
disclosed comprising a modular building roof structure in
combination with a suspended acoustical ceiling system, the
combination comprising a modular building roof structure comprising
a plurality of truss structures each having a top and a bottom; a
pair of deck layers attached to and for transversely. spanning the
tops of the truss structures; and an acoustical ceiling suspended
along the bottoms of the truss structures; and a modular building
floor structure comprising a deck structure including an upper deck
pan and a lower deck pan disposed opposite and adjacent each other
to create a plurality of spaced apart support channels; and a
plurality of support beams for supporting the deck structure;
wherein the deck and the acoustical ceiling define a return air
plenum. In a preferred embodiment, the deck structure is oriented
transverse to the support beams.
[0010] Other objects, aspects, and advantages of the invention will
be apparent upon a thorough reading of the detailed description
below along with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Embodiments of the invention are disclosed with reference to
the accompanying drawings and are for illustrative purposes only.
The invention is not limited in its application to the details of
construction or the arrangement of the components illustrated in
the drawings. The invention is capable of other embodiments or of
being practiced or carried out in other various ways. Like
reference numerals are used to indicate like components.
[0012] FIG. 1 is a perspective view of a group of modular building
structures according to one aspect of the present invention;
[0013] FIG. 2 is a top plan view of a plurality of modular building
structures;
[0014] FIG. 3A is a cut-away partial perspective view of the
modular building structure taken along line 3A-3A of FIG. 1;
[0015] FIG. 3B is an alternative embodiment of the perspective view
of the modular building structure of FIG. 3A showing the use of an
I-beam dual deck pan floor construction;
[0016] FIG. 3C is a is an alternative embodiment of the perspective
view of the modular building structure of FIG. 3A showing the use
of an I-beam dual deck pan floor construction in addition to a dual
deck pan roof construction;
[0017] FIG. 4 is a cross-sectional view of the modular building
structure taken along line 4-4 of FIG. 1;
[0018] FIG. 5 is a cross-sectional view taken along line 5-5 of
FIG. 4;
[0019] FIG. 6 is an enlarged sectional view taken along line 6-6 of
FIG. 4 showing a portion of the modular building roof
structure;
[0020] FIG. 7 is an enlarged sectional view taken along line 7-7 of
FIG. 4 showing a portion of the modular building floor
structure;
[0021] FIG. 8 is an enlarged cross-sectional view taken along line
8-8 of FIG. 4 showing a portion of the modular building roof
structure with a return air plenum according to one aspect of the
present invention;
[0022] FIG. 9A is an enlarged cross-sectional view taken along line
9A-9A of FIG. 7 showing the pair of deck pans according to one
aspect of the present invention;
[0023] FIG. 9B is an alternative embodiment of the pair of deck
pans shown in a spaced apart arrangement; and
DETAILED DESCRIPTION OF THE INVENTION
[0024] Referring to FIG. 1, a perspective view of a group of
modular building structures 10 are shown. The group includes any
number (as indicated by the hashed lines) of individual structures
12a-d, such as modular structure 12b, which can be aligned or
positioned in a repeatable fashion as shown according to the space
requirements for the particular application. In the embodiment
shown, the modular units include roof structures 18 having a pitch
with an apex along centerline 21. In select applications, the roof
structures 18 can be constructed in a flattened manner to the
extent that modular units can be stacked to facilitate
transportation of multiple units to specific locations. In general,
if stacking of the modular structures is desired, as is
contemplated in multi-story applications of the present invention,
the roof structure pitch is typically reduced or eliminated
altogether. Applications for modular building structures such as
that shown in FIG. 1 include office, educational, health or
medical, laboratory space, residential, and light manufacturing,
among others. In a typical construction, each modular building unit
can include such features as doors 14 and windows 16, replicating
features found in permanent building structures. Each individual
structure or module 12a-d has in and of itself the requisite
elements to resist the lateral loads due to winds and earthquake
conditions. Advantageously, the lateral loads resistance or lateral
load bearing characteristics are also additive. That is, when the
structures are placed next to one another side to side, the lateral
load resistance is additive. Therefore, providing one structure
with x lateral load resistance level next to another structure with
y lateral load resistance, an additive effect of x+y total lateral
load resistance will be achieved. The combined structure will be
able to withstand the combined individual additive lateral loads.
When a plurality of the modular buildings are placed laterally
together to create a modular building group having a total lateral
load bearing characteristic, the total lateral load bearing
characteristic is additive from the individual modular building
lateral load bearing characteristics.
[0025] FIG. 2 is a top plan view of a plurality 20 of modular
building structures 22a-e. In structure 22d, a portion of the
modular building structure interior 24 is shown along with several
interior elements 26 (e.g., a sink, a toilet, a door, etc.). In the
embodiment shown, the modular structures are shown positioned in
side-by-side or adjacent fashion, however, it is contemplated that
the modular units can be arranged or positioned in ways that can
vary to convenience. In addition, the modular units are scaleable,
both in size and number, depending on the application at hand.
[0026] FIG. 3A is a cut-away partial perspective view of modular
building structure 10 taken along line 3A-3A of FIG. 1. In FIG. 3A,
various components and layers are illustrated in cutaway fashion to
facilitate understanding of the invention. FIG. 4 is a
cross-sectional view of the modular building structure 10 taken
along line 4-4 of FIG. 1.
[0027] Referring to FIGS. 3A and 4, modular building structure 10
includes a modular building roof structure 32 and a modular
building floor structure 34. The modular building roof structure 32
includes a plurality of longitudinal, open web trusses 36. Each of
the plurality of trusses 36 has a first end 38 (FIG. 3A) and a
second end 40 opposite the first end. Tubular columns 42 may be
positioned at the first and second ends 38, 40 of the trusses 36
for supporting the trusses. The ends 38,40 of the trusses 36 may
also be supported by a two-dimensional frame in order to reduce the
number of columns required Each truss or truss structure 36
includes longitudinally disposed supporting beams 46 and 48
connected in overlapping or "sandwiched" fashion using tension and
compression members 50. The beams 46 and 48 are, in the embodiment
shown, comprised of individual support beam members 46a,b and
48a,b. A deck 52 is attached to and spans the tops 35 of the truss
structures 36. In one embodiment, the deck is roll-formed and can
be made of steel. A suspended acoustical ceiling 54, which may be
of a ceiling tile variety, can be suspended along the bottoms 39 of
the trusses and in this fashion be combined with the modular roof
structure 32.
[0028] Significantly, the deck 52 and the suspended acoustical
ceiling define a return air plenum space 56. The return air plenum
space 56, in combination with any physical vents, provides for
proper venting, distribution and circulation of air, including
introduction of fresh air, throughout the modular structure. As a
result of the present structural arrangement, no separate ductwork
or duct system is required, which provides savings in the
manufacture, both in terms of material and labor costs, of the
modular building structure of the present invention. Preferably, at
least one of the plurality of longitudinal, open web trusses, the
plurality of tubular columns, and the roll-formed deck can be
constructed of steel, and in a preferred embodiment, the deck 52 is
substantially covered with a mold-resistant foam insulation
material 57. Accordingly, the modular building roof structure 32
can be described as substantially non-combustible and substantially
mold-resistant.
[0029] The modular building structure 10 further includes a modular
building floor structure 34 which is joined or connected to the
roof structure 32 as shown via columns 42. The floor structure 34
includes a single layer deck structure 58. A plurality of
longitudinal main support beams 60, also called "Z purlins", are
connected to the deck pans and are oriented transverse to the
length of the floor structure. Advantageously, the present
invention provides for the ability of the support beams to be
positioned in spaced apart fashion, typically about 12 to 14 feet
apart over the entire length of the modular building unit. End
support beams or "I-beams" 62 are utilized at the outer region of
the floor structure. In one embodiment, a decking surface 64,
typically of a plywood, cement board, poured concrete or
combination type, can be connected to, positioned or laid over, or
otherwise formed over, the pair of deck pans. As an additional
feature, wheels 66 can be provided to improve the mobility of the
modular unit.
[0030] FIG. 3B is an embodiment of the perspective view of the
modular building structure 10 of FIG. 3A showing an improvement
through the use of an I-beam dual deck pan floor construction 61
for use in the overall floor structure 34. The z purlins of FIG. 3A
are replaced here on each edge with an I beam 63 that runs the
length of the building 10. Although not shown, the opposite edge
would mirror the edge shown to complete the floor structure.
Advantageously, the result is the use of fewer heavy metal
construction components. Specifically, the plurality of transverse
z-purlins are replaced by only two I beams that run the length of
module 10. The benefits conferred by I-beams 63 include: reduction
of construction costs of module 10, reduced overall weight, and
reduced material (which reduced material transportation costs),
among others. A pair of deck pans 65 is utilized in order increase
strength. The pair are oriented to be transverse to the length of
the I-beams such that the ribs of the pair run the width of module
10. It is the increased strength of the transverse deck pan pair 65
that helps permit the use of the longitudinal I beams 63, and at
longer intervals between beams, to reduce the number of support
beams required overall. The traverse dual decking 65 and the
lengthwise I-beams 63 together make up the I-beam dual deck pan
floor construction 61 for use in the overall floor structure
34.
[0031] FIG. 3C is a is an alternative embodiment of the perspective
view of the modular building structure of FIG. 3B showing the use
of an I-beam dual deck pan floor construction 61 in addition to a
dual deck pan roof construction 71. By "dual deck pan roof
construction" it is meant that the roof construction comprises two
main trusses 73, 75 along with a pair of deck pans 77, 79. Again,
the dual pans provide additional structural support when compared
to a single deck pan arrangement. The increased strength permits
the weight of the roof to be supported by few trusses, as shown,
trusses 73, 75, without deleterious effects such as buckling or
significant bending. The benefits conferred by the roof structure
shown include: reduction of construction costs, reduced overall
weight, and reduced material (which reduce material transportation
costs), among others.
[0032] FIG. 6 is an enlarged sectional view taken along line 6-6 of
FIG. 4 showing a portion of the modular building roof structure 32.
Support member 46b and 48b are connected via tension and
compression members 50. Decking 52 is attached at its lower surface
68 to the top of truss 36, and specifically as shown to member 46b.
1.5" deck is one material that is suitable for use in the present
invention. Acoustical ceiling 54, which is typically made of an
insulation material, is attached at its upper surface 70 to decking
52 through the use of suspension wires. The roof structure and
ceiling create combination 37. Decking 52 and ceiling 54 create
return air plenum 56. Again, as a result of the present structural
arrangement, no separate return air ductwork or duct system is
required, the modular building structure of the present invention
can be constructed for less money with fewer materials and with a
less complicated air distribution system. Truss 36 is supported at
its end by column 42. Various supports 72 include, as shown,
2.times.2 or 2.times.4 wood supports members. A roofing material 74
(e.g., 0.060 in. EPDM) can be laid or applied to the upper surface
of the foam insulation 57. The roofing material can be secured, for
example, to trim 76. Supports 72 are connected and secured to the
truss 36 via a track 78, such as a "C" track, and covered by the
roofing material 74. Other paneling 80 and trim elements 82 can be
added to complete the exterior of the roofing structure as
desired.
[0033] FIG. 8 is an enlarged cross-sectional view taken along line
8-8 of FIG. 4 showing a portion of modular building roof structure
32 with plenum 56. Space or plenum 56 runs, in a preferred
embodiment, substantially the entire length of the modular building
roof structure. Again, in a known fashion, the plenum is defined by
the deck 52 at its upper boundary and the ceiling insulation
material 54 on its lower boundary, as well as, by thermal
insulation material 76 on its ends. The deck and ceiling are
connected by truss 36.
[0034] Referring to FIG. 5, a cross-sectional view taken along line
5-5 of FIG. 4 is shown. As can be seen, a portion of the modular
building structure is shown, illustrating several basic structural
members. These members include tubular members 42, "C" beams 44,
which, in conjunction with stud members 45 serve to provide the
requisite support for the trusses and connects the roof structure
with the floor structure of the modular building unit. Also, these
members eliminate the need for intermediate support or support
members within the overall modular building structure. Exterior
panels 47 are also included to protect the exterior surface of the
modular building structure.
[0035] FIG. 7 is an enlarged sectional view taken along line 7-7 of
FIG. 4 showing a portion of the modular building floor structure
34. Support beams, such as I-beam 62 and Z-purlins 60 which are
shown in exemplary fashion, are used to support the deck pan 58
(with I-beams being used in transverse fashion when supporting dual
layer deck pans). Again, foam insulation 82, paneling 84 and trim
86 are used to provide protection and buttress the support beams.
Stud 88, preferably made of steel, provides the support necessary
for the dual pans 58 to withstand the stresses imposed thereon. A
steel strap 89 is shown for use in supporting insulation (not
shown) which can be inserted or placed in space 93 located above
the strap. The strap runs through center punches 91a-b (also called
eyelits) in I-beam 62 and Z-beam 60.
[0036] FIG. 9A is an enlarged cross-sectional view taken along line
9A-9A of FIG. 7 showing deck structure pair 65 of deck pans. In one
embodiment, 1.5" deck is one material that is suitable for use in
the present invention, although other materials are possible and
contemplated. More specifically, an upper deck pan 90 and a lower
deck pan 92 are positioned in opposing adjacent fashion to create
the deck support. The positioning of the pans 90, 92 create support
channels 94, spaced apart by regions 96 in which the pans contact
or substantially contact each other. One manner of accomplishing
this arrangement is to take a first rolled, corrugated deck pan,
and position it in opposing fashion with a similar, if not
identical, second deck pan. The arrangement illustrated promotes
maximum strength and rigidity for the modular floor structure,
while minimizing the need for additional or unnecessary floor
structure support members. Additionally, bending or other
deflection of the floor structure is also minimized. As a result,
the deck structure is capable of supporting a greater load than
each of one of the pair of deck pans individually. Also, the deck
structure has a combined deflection level that is less than an
individual deflection level for each of the deck pans individually
for a given load. Advantageously, the strengthening can be
accomplished using materials, such as those described herein, that
are common in the modular building industry. Moreover, it is
contemplated to add or insert materials into channels 94, with the
insertion of said additional materials adding to the strength of
deck structure pair 58.
[0037] FIG. 9B is an alternative embodiment of the pair of deck
pans 90, 92 shown in a adjacent and opposed relationship with a
spaced apart arrangement to create gaps 95. This arrangement can be
used on the roof structure in addition to the floor structure of
the present invention. In the embodiment shown, spacers 97 are
inserted into gaps 95 to provide a separation between deck pan 90
and pan 92, and more specifically, to separate deck pan interior
surfaces 99, 101. Here, in regions 103, the deck pans contact
spacers rather than the opposing deck pans directly. Significantly,
spacers 97 provide for enhanced load distribution for a given load.
Resultantly, when compared to a single layer deck pan, and even
some dual deck pan arrangmenets, for steel deck pans of a given
gauge, a greater load can be distributed, and alternatively, for a
given load, the embodiment of FIG. 9B permits the use of a lighter
gauge steel.
[0038] While the present invention has been described in terms of
the preferred embodiment, it is recognized that equivalents,
alternatives, and modifications, aside from those expressly stated,
are possible and within the scope of the appending claims.
* * * * *