U.S. patent application number 12/483157 was filed with the patent office on 2009-12-17 for module with moment frame and composite panels for a building structure.
This patent application is currently assigned to Veristeel, Inc.. Invention is credited to Scott CATHCART, Chris Ransel.
Application Number | 20090307994 12/483157 |
Document ID | / |
Family ID | 41413473 |
Filed Date | 2009-12-17 |
United States Patent
Application |
20090307994 |
Kind Code |
A1 |
CATHCART; Scott ; et
al. |
December 17, 2009 |
MODULE WITH MOMENT FRAME AND COMPOSITE PANELS FOR A BUILDING
STRUCTURE
Abstract
A module for building structure includes a moment frame, a set
of four top corner pieces, and a set of two or more composite
panels. The moment frame is comprised of beams and columns jointed
to form a top, a bottom and four sides. Each top corner piece is
located at a corner of the top of the moment frame. The set of two
or more composite panels is attached to the bottom of the moment
frame to provide a sub-floor of the building structure. A first
composite panel, of the set, is adapted to transfer a load to a
second abutting composite panel of the set, in response to a
deflection of the moment frame. Each composite panel is comprised
of a core element encased in a metal frame, which includes two face
sheets, two end cap pieces, and two side pieces.
Inventors: |
CATHCART; Scott; (North Las
Vegas, NV) ; Ransel; Chris; (North Las Vegas,
NV) |
Correspondence
Address: |
MORRISON & FOERSTER LLP
425 MARKET STREET
SAN FRANCISCO
CA
94105-2482
US
|
Assignee: |
Veristeel, Inc.
North Las Vegas
NV
|
Family ID: |
41413473 |
Appl. No.: |
12/483157 |
Filed: |
June 11, 2009 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61131957 |
Jun 13, 2008 |
|
|
|
Current U.S.
Class: |
52/79.9 ;
52/653.1; 52/655.1; 52/782.1; 52/794.1 |
Current CPC
Class: |
E04B 2001/34892
20130101; E04C 2/246 20130101; E04C 2/243 20130101; E04B 1/3483
20130101 |
Class at
Publication: |
52/79.9 ;
52/653.1; 52/794.1; 52/655.1; 52/782.1 |
International
Class: |
E04C 3/29 20060101
E04C003/29; E04C 2/36 20060101 E04C002/36; E04C 2/30 20060101
E04C002/30; E04C 2/02 20060101 E04C002/02; E04H 1/00 20060101
E04H001/00 |
Claims
1. A module for a building structure comprising: a moment frame
comprised of beams and columns joined to form a top, a bottom and
four sides; a set of four top corner pieces, each top corner piece
located at a corner of the top of the moment frame, each top corner
piece having a coupler element to interface with a lifting
mechanism that lifts the module; and a set of two or more composite
panels attached to the bottom of the moment frame to provide a
sub-floor of the building structure, wherein a first composite
panel of the set is adapted to transfer a load to a second abutting
composite panel of the set, in response to a deflection of the
moment frame, wherein each composite panel comprises: a metal frame
having two face sheets, two end cap pieces and two side pieces,
wherein the two face sheets are substantially parallel, the two end
cap pieces are substantially perpendicular to the face sheets, and
the two side pieces are substantially perpendicular to both the
face sheets and the end cap pieces; and a core element encased
within the metal frame, wherein the core element is bonded to the
two metal face sheets.
2. The module of claim 1, wherein each side piece is a metal sheet
formed to create an interlocking joint piece, wherein the
interlocking joint piece includes a channel shape and a protrusion
shape extending the length of the interlocking joint piece.
3. The module of claim 2, wherein the channel shape of an
interlocking joint piece of the first composite panel interconnects
with protrusion shape of the interlocking joint piece of the second
composite panel.
4. The module of claim 3, wherein the interlocking joint piece is
adapted to provide vertical support for a second composite panel
abutting the first composite panel.
5. The module of claim 3, wherein the interlocking joint piece of
the first composite panel is further adapted to transfer a
compression load to the second composite panel abutting the first
composite panel.
6. The module of claim 3, wherein the composite panels are adapted
to support a compression load in response to the module being
subjected to a moment load.
7. The module of claim 1, wherein the metal frame is made of steel,
and wherein the core element is made of foam.
8. The module of claim 1, further comprising, a second set of two
or more composite panels, wherein the second set of two or more
composite panels is attached to the top of the moment frame to
provide a ceiling of the building structure.
9. The module of claim 8, wherein the second set of composite
panels that provide the sub-floor comprises different materials
than the set of composite panels that provide the ceiling.
10. The module of claim 1, further comprising, ledgers attached to
at least two beams in the frame, wherein the set of two or more
composite panels is attached to the ledgers.
11. The module of claim 1, wherein the set of two or more composite
panels provide the sub-floor of a first module and the same
composite panels provide a ceiling of a second module, wherein the
second module is mounted below the first module.
12. The module of claim 1, wherein each of the set of four top
corner pieces having a coupler element comprises: three external
faces and three slotted holes, each slotted hole extending inward
from each of the three external faces.
13. The module of claim 1, wherein each of the four top corner
pieces is comprised of an ISO corner casting.
14. The module of claim 1, further comprising, a set of four bottom
corner pieces, each bottom corner piece located at a corner of the
bottom of the moment frame, each bottom corner piece having a
coupler element to interface with a securing mechanism that secures
the module.
15. The module of claim 14, wherein each of the set of four bottom
corner pieces having a coupler element comprises: three external
faces and three slotted holes, each slotted hole extending inward
from each of the three external faces.
16. The module of claim 14, wherein each of the four bottom corner
pieces is comprised of an ISO corner casting.
17. The module of claim 1, wherein the bottom of the moment frame
has approximately the footprint of a standard 8.times.20 cargo
container.
18. The module of claim 1, wherein the bottom of the moment frame
has approximately the footprint of a standard 8.times.40 cargo
container.
19. The module of claim 1, wherein the bottom of the moment frame
has an outside width of approximately 8 feet and an outside length
of about 20 feet.
20. The module of claim 1, wherein the bottom of the moment frame
has an outside width of approximately 8 feet and an outside length
of about 40 feet.
21. The module of claim 1, wherein the beams are comprised of a
steel channel with a cross-section ranging between 150 mm to 250 mm
in height and between 60 mm and 120 mm in width.
22. The module of claim 1, wherein the columns are comprised of a
steel rectangular tube with a cross-section ranging between 120 mm
to 180 mm in height and width.
23. The module of claim 1, further comprising, a roof panel
section, wherein the roof panel section includes one or more
corrugated steel sheet pieces, each sheet piece welded along the
edge to create a water resistant seam.
24. The module of claim 23, wherein the roof panel section is
formed into a convex shape to direct water to the edges of the
module.
25. The module of claim 1, further comprising, a pitched-roof
section, wherein the pitched roof includes at least one flat panel
piece and at least one weather resistant sheet attached to the top
of the flat panel piece.
26. The module of claim 25, wherein the flat panel piece is a
composite panel.
27. The module of claim 25, wherein the pitched-roof section
includes a single pitch of 1/8 inch rise per foot of length.
28. The module of claim 25, wherein the pitched-roof section
includes a double-pitch section of 1/4 inch rise per foot of
length, and wherein the top of the double-pitch section is in a
center of the module.
29. The module of claim 1, wherein another set of two or more
composite panels form a side wall of the module.
30. The module of claim 29, wherein a first composite panel of the
set forming the side wall interconnects with an abutting second
composite panel of the set forming the side wall.
31. A modular system for constructing a building structure,
comprising: two or more modules joined together to form a portion
of the building structure, each module comprising: a moment frame
comprised of beams and columns joined to form a top, a bottom, and
four sides; a set of four top corner pieces, each corner piece
located at a corner of the top of the moment frame, each corner
piece having a coupler element to interface with a lifting
mechanism that lifts the module; and a set of two or more composite
panels attached to the bottom of the moment frame to provide a
sub-floor of the building structure, wherein each composite panel
comprises: a metal frame having two face sheets, two end cap pieces
and two side pieces, wherein the two face sheets are substantially
parallel, the two end cap pieces are substantially perpendicular to
the face sheets, and the two side pieces are substantially
perpendicular to both the face sheets and the end cap pieces; and a
core element encased within the metal frame, wherein the core
element is bonded to the two metal face sheets.
32. The modular system of claim 31, wherein the two or more modules
are joined side-by-side to one another to form a portion of one
story of the building structure.
33. The modular system of claim 31, wherein the sets of two or more
composite panels of the two or more modules are attached to the
bottoms of the two or more modules, and wherein adjacent sides of
side-by-side modules are left open to create a clear span for the
building structure.
34. The modular system of claim 31, wherein the two or more modules
are joined one on top of another to form multiple stories of the
building structure.
35. The module system of claim 34, wherein the two or more modules
comprise: a first type of modules, wherein the first type of
modules forms an upper most story of the building structure,
wherein the sets of two or more composite panels of the first type
of modules are attached to the top of the moment frame with top
metal face sheets of the sets of the two or more composite panels
being substantially flush with tops of the beams that form the top
of the first type of modules.
36. A module for a building structure comprising: a moment frame
comprised of beams and columns joined to form a top, a bottom and
four sides; a set of four top corner pieces, each top corner piece
located at a corner of the top of the moment frame, each top corner
piece having a coupler element to interface with a lifting
mechanism that lifts the module; and a set of four bottom corner
pieces, each bottom corner piece located at a corner of the bottom
of the moment frame, each bottom corner piece having a coupler
element to interface with a securing mechanism that secures the
module.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional
Application Ser. No. 61/131,957 filed Jun. 13, 2008, which is
incorporated herein by reference in its entirety for all
purposes.
BACKGROUND
[0002] 1. Field
[0003] This application relates generally to modular building
construction and, more specifically, to using a modular building
moment frame to construct rapidly deployable structures that can be
used to house or shelter people.
[0004] 2. Description of the Related Art
[0005] Known methods of building construction can be used to
provide homes, schools, medical facilities and other essential
structures. While traditional construction methods can be applied
to a wide range of applications, traditional methods may require
significant lead time, raw materials, and skilled labor
resources.
[0006] For example, portions of a building structure may require
custom fabrication that must be performed at the building site.
This presents at least three constraints on a traditional
construction project. First, it may be necessary to deliver large
amounts of raw materials to the building site. The raw materials
must be stored, protected from the elements and secured from theft.
Second, a skilled labor force may be required to fabricate each
element of the building structure using the raw materials provided.
Foundations, walls, floors, ceilings and roofs may be fabricated by
hand and integrated into the building piece by piece. Third,
traditional methods may require a substantial lead time between the
perceived need for a building and the completion of a working
facility. Traditional projects typically require time to design,
draft, and procure materials before fabrication can begin. Planning
and executing even a small construction project may require months
of advanced planning. Large scale projects may require years.
[0007] The time constraints due to traditional methods may be
unacceptable for projects that require an accelerated build
schedule. Traditional methods may also be unsuitable for projects
with limited access to raw materials or skilled labor. For example,
exigent circumstances, such as military troop deployment, natural
disaster relief, or population displacement, present immediate
needs in areas that may be far removed from traditional
construction resources.
[0008] In many cases, modular construction may overcome limitations
of traditional construction techniques. By prefabricating portions
of the structure off-site, lead time can be reduced, and fewer raw
materials may be required on-site for the final construction.
Prefabricated modules can be manufactured ahead of time, stored,
and then shipped to the final location once a facility is needed.
Modules can also be configured on-site into a wide range of
facilities and custom tailored to the needs of the occupant.
Additionally, modules designed to facilitate on-site assembly may
reduce the need for large numbers of skilled construction
workers.
[0009] What is needed is a modularized structural building system
that can be customized and manufactured in scalable quantities, and
deployed world wide.
SUMMARY
[0010] A module for building structure includes a moment frame, a
set of four top corner pieces, and a set of two or more composite
panels. The moment frame is comprised of beams and columns jointed
to form a top, a bottom and four sides. Each top corner piece, of
the set of four top corner pieces, is located at each corner of the
top of the moment frame. Each top corner piece has a coupler
element to interface with a lifting mechanism that lifts the
module. The set of two or more composite panels is attached to the
bottom of the moment frame to provide a sub-floor of the building
structure. A first composite panel, of the set, is adapted to
transfer a load to a second abutting composite panel of the set, in
response to a deflection of the moment frame. Each composite panel
is comprised of a metal frame having two face sheets, two end cap
pieces, and two side pieces. The two face sheets are substantially
parallel to each other, the two end cap pieces are substantially
perpendicular to the face sheets, and the two side pieces are
substantially perpendicular to both the face sheets and the end cap
pieces. Each composite panel is further comprised of a core element
encased within the metal frame, and bonded to the two metal face
sheets.
DESCRIPTION OF THE FIGURES
[0011] FIG. 1A illustrates an exemplary embodiment of a building
structure composed of multiple moment modules.
[0012] FIG. 1B illustrates an alternate embodiment of a building
structure composed of multiple moment modules.
[0013] FIG. 1C illustrates a sectional cut-away view of a building
structure, including a gable roof structure.
[0014] FIG. 2 illustrates a moment module.
[0015] FIG. 3 illustrates an interlocking panel joint.
[0016] FIG. 4 illustrates a moment frame.
[0017] FIGS. 5A to 5B illustrate 8.times.20 foot and 8.times.40
foot moment modules.
[0018] FIG. 6 illustrates a range of moment module sizes.
[0019] FIG. 7 illustrates a moment module with composite panels
installed in both the bottom and top of the moment frame.
[0020] FIG. 8 illustrates a type T moment module.
[0021] FIG. 9 illustrates a type-U moment module.
[0022] FIG. 10 illustrates a moment module with a single-pitch
roof.
[0023] FIG. 11 illustrates a moment module with a double-pitch
roof.
[0024] FIG. 12 illustrates a drainage system for a moment
module.
[0025] FIG. 13 illustrates a moment module with side walls.
[0026] FIGS. 14A to 14H illustrate components of a composite panel
assembly.
[0027] FIGS. 15A to 15H illustrate components of an alternative
embodiment of a composite panel assembly.
[0028] FIG. 16 illustrates the profile of an interlocking joint
piece.
[0029] FIGS. 17A to 17C illustrate one embodiment of a face
sheet.
[0030] FIGS. 18A to 18C illustrate an alternate embodiment of a
face sheet.
[0031] FIGS. 19A to 19C illustrate one embodiment of an end
cap.
[0032] FIGS. 20A to 20C illustrate an alternative embodiment of an
end cap.
[0033] FIG. 21 illustrates an example of a flat pattern of an end
cap.
[0034] FIG. 22 illustrates an example of mounting a composite panel
using a ledger configuration.
[0035] FIG. 23 illustrates an example of mounting a composite panel
directly to a beam member.
[0036] FIGS. 24A and 24B illustrate an elevation view and detail
view of a lower frame corner.
[0037] FIGS. 25A and 25B illustrate an elevation view and detail
view of an upper frame corner.
[0038] FIGS. 26A and 26B illustrate an elevation view and detail
view of an alternative upper frame corner.
[0039] FIGS. 27A and 27B illustrate a corner interface of four
moment modules in a building structure.
[0040] FIGS. 28A to 28F illustrate moment modules assembled into a
building structure.
[0041] FIG. 29 illustrates a three by three moment module
structure.
[0042] FIGS. 30A to 30C illustrate alternative configurations of a
building structure using moment modules.
[0043] The figures depict one embodiment of the present invention
for purposes of illustration only. One skilled in the art will
readily recognize from the following discussion that alternative
embodiments of the structures and methods illustrated herein can be
employed without departing from the principles of the invention
described herein.
DETAILED DESCRIPTION
[0044] Modularized steel moment frames can be used to construct
scalable building structures for immediate deployment anywhere in
the world. The following embodiments describe how different
variations of a rapidly deployable and stackable moment module
(referred to simply as "moment module" hereafter) can be
fabricated, shipped and assembled on-site to help create a variety
of building facilities.
[0045] FIGS. 1A to 1C depict moment modules assembled together to
form examples of a building structure. In FIG. 1A, a 3 story
building structure is formed using 3 stacks of 12 moment modules
for a total of 36 moment modules. As discussed in greater detail
below, a moment module 100 can be adapted in a variety of ways to
form a completed building facility 110. As shown in FIG. 1A, a
moment module 100 can include stairs, external walls, windows and
other traditional building features. FIG. 1B depicts another
example of a building structure 120 featuring a fully enclosed,
internal stairway.
[0046] FIG. 1C depicts multi-story building 110 in a cut-away view.
As discussed in greater detail below, the moment module 100 allows
for an open span, which allows for a floor plan that is free from
internal columns or load-bearing walls.
[0047] A completed building 110 may also include a gable roof
structure 140. The gable roof structure 140 may be constructed
using composite panels or more traditional wooden truss
construction and roofing materials. The roof structure may also be
constructed of a hybrid of composite panels and traditional
building materials. For additional descriptions of composite panels
being used to provide a roof structure, see U.S. Pat. No.
6,588,171, which is incorporated herein by reference in its
entirety for all purposes. In alternative embodiments described
herein, the roof structure may also be integrated into individual
moment modules that make up the top floor in a building.
1. Moment Module
[0048] As mentioned above, the moment modules can be used as the
fundamental structural elements in a variety of building
construction configurations. Creating a building structure using
moment modules, as described herein, allows for a majority of the
fabrication to be performed off-site. The completed or partially
completed moment modules can then be shipped to the location of the
building, and assembled into place. As depicted in FIGS. 2 to 13,
moment modules can be constructed in a variety of configurations to
provide features that are suited to a particular application.
[0049] FIG. 2 is a perspective view of moment module 100, including
a moment frame 210 and a set of two or more composite panels 220,
which forms the floor or sub-floor of moment module 100. In one
alternative embodiment, a single composite panel may be used to
form the floor or sub-floor. In another alternative embodiment, the
floor or sub-floor is constructed using materials that are not
composite panels.
[0050] The moment frame 210 includes eight beams 212 and four
columns 214, which are joined to form a top, bottom, and four
sides. The four sides of the moment module 100 can be left open
because the columns 214 of the moment frame 210 can provide
sufficient structural integrity without requiring the use of
load-bearing panels/walls.
[0051] In FIG. 2, two or more composite panels are attached to the
bottom of moment frame 100. Each composite panel 220 may be
attached using ledger frame elements and threaded fasteners as
described in more detail below. Once installed, the two or more
composite panels become a structural member of the moment module
100. For example, in some embodiments, the moment module 100,
including two or more composite panels, is able to distribute floor
loads up to or in excess of 240 kg/m.sup.2 (approximately 50
lbs/ft.sup.2).
[0052] In some embodiments, the composite panels are able to
distribute bending or twisting loads exerted on the moment module.
Because the composite panels are physically integrated into the
moment frame 210, the composite panels are able to resist a
deflection or deformation in the moment frame. For example, each
composite panel 220 (of the set of composite panels) is able to
resist a moment load, particularly if the moment load is
perpendicular to a face sheet of the composite panel. (See section
3 below for a description of composite panel components.). By
attaching the composite panel 220 to a beam 212 in the moment frame
210, the composite panel 220 is able to impede a deflection of the
beam by resisting the moment load created by the beam deflection.
This is particularly true for deflections that result in a moment
that is perpendicular to the face sheet of the composite panel.
[0053] Thus, each individual composite panel 220 is able to provide
additional rigidity or structural support to the moment frame 210.
In addition, each composite panel 220 is able to distribute loads
to other, abutting composite panels. For example, FIG. 3 depicts an
exemplary embodiment of an interlocking panel joint between
abutting composite panels 220.
[0054] In some embodiments, the composite panels 220 may include
interlocking joint pieces along two sides of composite panel 220.
Preferably formed from steel sheet, the interlocking joint pieces
can be used to locate and support the composite panels 220 when
they are installed in moment frame 210. FIG. 3 depicts an exemplary
side detail of two composite panels 220 joined together using
interlocking joint pieces 234. In some embodiments, the
interlocking joint pieces 234 may form the side piece of the
composite panel 220. For a detailed description of the composite
panel construction, see section 3, below.
[0055] Exemplary embodiments of the interlocking joint pieces 234
have a protrusion shape 236 and a channel shape 238. Both shapes
are formed into the metal sheet and extend the length of the
interlocking joint piece. When assembled in the moment frame, the
protrusion shape 236 of the interlocking joint piece can be
inserted into the channel shape 238 of another interlock joint
piece, to form an interlocking panel joint between two abutting
composite panels.
[0056] The interlocking panel joint resists relative movement of
the composite panels in at least the direction perpendicular to the
joint. For example, if the panels are horizontal as shown in FIG.
3, the joint resists relative movement in the vertical direction.
By resisting vertical motion, the joint is able to withstand sheer
loads between the composite panels. For example, if the composite
panels are used to create the floor of the moment module, the joint
can support vertical sheer loads created by the weight of objects
in contact with the floor of the moment module.
[0057] In a preferred embodiment, the protrusion shape 236 of the
interlocking joint piece is deeper than the channel shape 238 of a
mating interlocking joint piece so that there is a gap between the
face sheets of the two abutting composite panels. Depending on the
strength of the material forming the protrusion shape 236, a
compression load may be transferred from one composite panel to
another, abutting composite panel. For example, a compression load,
substantially parallel to the face sheet of the composite panel and
perpendicular to the panel joint may be transferred from one
composite panel to a second, abutting composite panel.
[0058] In some embodiments, the panel joint may also resist
torsional or twisting loads between two composite panels. This may
also increase the rigidity of the moment module when a set of two
or more composite panels are installed in the moment frame. For
example, if the moment frame is subjected to a torsional or
twisting load, the beams in the moment frame may deflect or
distort. As discussed above, this deflection may be resisted by
each composite panel that is mounted to a deflecting frame member
due to the rigidity or stiffness of each individual composite
panel.
[0059] Additionally, the moment frame deflection may be resisted
due to the panel joint between abutting pairs of composite panels.
As the moment frame is distorted, a first composite panel may tend
to shift with respect to a second, abutting composite panel. The
panel joint, however, resists this shifting by resisting relative
movement of the two composite panels in a direction that is
perpendicular or transverse to the panel joint. By resisting this
transverse motion, the two abutting panels are able to distribute a
transverse load created by the frame distortion. Additionally, the
panel joint may resist a movement of the composite panels in a
direction that is substantially parallel to the face sheet of the
composite panels and perpendicular to the panel joint. By resisting
motion in this direction, the two abutting panels are able to
distribute a compression load created by the frame distortion.
Thus, depending on the deflection of the moment frame, the panel
joint may transfer a compression load, a transverse load, or a
combination of the two loads from a first composite panel to a
second, abutting composite panel.
[0060] In some embodiments, the panel joint connects a set of
composite panels such that the combined and joined panels exhibit
properties similar to a single continuous panel. As described
above, the panel joint may resist motion of the composite panels in
a direction parallel to the face sheet of the composite panel, and
in a direction transverse or at an angle to the face sheet of the
composite panel.
[0061] The amount of rigidity or support created by the set of
composite panels may also be reduced. Depending on the clearance
between the mating faces in the joint, the panels may also be
allowed to shift with respect to each other to comply with a
certain amount of deformation or planar twist in the moment module
frame.
[0062] Note that FIG. 3 depicts the composite panels 220
horizontally mounted in a moment frame. However, various
embodiments may use the composite panels 220 with interlocking
panel joints in other configurations or in conjunction with other
elements of the structure, such as composite panels used in a wall,
ceiling or roof panel structure.
[0063] FIG. 4 depicts a perspective view of the moment frame 210 of
the moment module 100 without composite panels. Four metal columns
214 are used to form the four sides of the moment frame. Eight
metal beams 212 are used to form the top and bottom of the moment
frame. The metal beams and columns can be made of any structural
grade steel or aluminum and may either be welded or connected using
metal fasteners (e.g., bolts or rivets). Alternatively, the beams
and columns could include different cross sections or could be
formed from metal sheet.
[0064] In some embodiments, the metal columns 214 may be made from
a closed cross-section rectangular tube with a 150 mm.times.150
mm.times.9 mm cross-section. In some embodiments, the metal beams
212 may be made from a 200 mm.times.90 mm.times.9 mm cross-section
steel channel.
[0065] The moment frame includes four top corner elements attached
to each corner of the top of the moment frame. In some embodiments,
the moment frame may also include four bottom corner pieces
attached to each corner of the bottom of the moment frame. FIG. 4
depicts an embodiment including four top corner pieces 216 attached
to the top of the moment frame and four bottom corner pieces 218
attached to the bottom of the moment frame. FIGS. 24-26 depict
specific examples of corner piece integration in more detail.
[0066] Each top corner piece includes a coupler element to
interface with a lifting mechanism that lifts the module. For
example, each top corner piece may include three external faces,
with a slotted hole on each face. The slotted holes project inward
to a hollow core of the top corner piece. In some embodiments, the
top corner pieces may be designed in accordance with standard ISO
freight container upper corner castings.
[0067] In some embodiments, the top corner pieces 216 can be used
to lift or load the moment module during transportation. For
example, if the top corner pieces 216 are ISO corner castings, the
module may be lifted using existing crane and hoist equipment
designed to move and transport traditional cargo shipping
containers.
[0068] Each bottom corner piece includes a coupler element to
interface with a securing mechanism that secures the module. For
example, each bottom corner piece may include three external faces,
with a slotted hole on each face. The slotted holes project inward
to a hollow core of the bottom corner piece. In some embodiments,
the bottom corner pieces may be designed in accordance with
standard ISO freight container lower corner castings.
[0069] In some embodiments, the bottom corner pieces 218 can be
used to secure the moment module to a deck or shipping platform.
For example, if the bottom corner pieces 218 are ISO corner
castings, the moment module may be secured to the bed of a truck or
deck of a boat designed to interface with traditional cargo
shipping containers. Additionally, if the corner pieces (top or
bottom) are ISO corner castings, the moment module may also be
stacked on top of or underneath a traditional cargo shipping
container. Similarly, the corner pieces (top or bottom) may also be
used to physically tie the moment module to another moment
module.
[0070] FIGS. 5A and 5B depict examples of two different sizes for
the moment module as moment modules 520 and 540, respectively. FIG.
5A depicts the moment module 520 as being approximately 9 feet, 6
inches tall by 8 feet wide by 20 feet long. The moment module 520
has approximately the dimensional footprint of a standard
8.times.20 cargo container. FIG. 5B depicts the moment module 540
as being approximately 9 feet, 6 inches tall by 8 feet wide by 40
feet long. The moment module 540 has approximately the dimensional
footprint of a standard 8.times.40 cargo container. FIG. 6 depicts
an end view and elevation view of a moment module with a range of
sizes. While this range includes the preferred embodiments
described in FIGS. 5A and 5B, the size of a moment module may
include embodiments outside of the range of values shown in FIG. 6.
In a preferred embodiment, the interior dimension of the moment
module provides a minimum 8 foot ceiling clearance. To provide for
increased ceiling height, moment modules can be made to an external
height of 11 feet, 6 inches.
[0071] Because the moment modules 520 and 540 have approximately
the same footprint as standard cargo containers, they can be
handled, transported, and/or relocated using existing
transportation and handling equipment available throughout the
world. As described above, if a module conforms to ISO
specifications, the moment module can be transported using trucks,
hoists, and ships that are used to transport standard cargo
containers. The moment modules can also be handled at building
sites and assembled using handling equipment adapted to interface
with standard cargo containers. In this way, moment modules can be
rapidly deployed throughout the world using existing transportation
infrastructure. It should be noted, however, that moment modules
can have various sizes and various shapes.
2. Moment Module, Configurations
[0072] A moment frame, composite panels and other structural
elements may be integrated to create various configurations of the
moment module. For example, one or more composite panels can be
used to construct the moment module floor, the moment module
ceiling, the moment module roof, and/or the moment module walls.
For a more detailed description of a composite panel, see sections
3 below.
[0073] In the moment module 710 depicted in FIG. 7, a top set and a
bottom set of two or more composite panels 220 are attached to the
bottom and top of the moment frame 210 to form a sub-floor and a
ceiling, respectively, of a building structure. Note, however, that
the set of composite panels attached to the bottom of the frame may
differ from the composite panels attached to the top of the
frame.
[0074] As described earlier, a moment module may include only the
first set of two or more composite panels attached to the bottom of
the moment frame to provide a sub-floor of a portion of a building
structure. Alternatively, a moment module may include only the
second set of two or more composite panels that can be attached to
the top of the moment frame to provide a ceiling of a portion of a
building structure. In some embodiments, a single composite panel
can be used to provide either the sub-floor or ceiling of a
building structure. In another alternative embodiment, the moment
module does not include any composite panels.
[0075] FIGS. 8 and 9 depict two types of moment modules. One moment
module is referred to herein as a type-T moment module 810, while
the other is referred to as a type-U moment module 910. As depicted
in FIG. 8, the type-T moment module 810 has composite panels
attached to the top of the moment module with the top of the panels
approximately flush with the top of the top beams of the moment
frame of the moment module. The type-T moment module 810 can be
used for a single story building or as the top floor of a
multi-story building. As depicted in FIG. 9, the type-U moment
module 910 has composite panels attached to the top of the moment
module with a space between the top of the panels and the top of
the top beams of the moment frame of the moment module. The type-U
moment module 910 can be used as the lower unit in multi-story
buildings. In some embodiments, the spacing can be used for wires,
plumbing, duct-work, etc.
[0076] FIGS. 10 and 11 depict moment modules with a single and
double-pitch roof, respectfully. The slope of the pitched roof
allows water to drain off the building structure. FIG. 10 depicts
moment module 1010 with a single-pitch roof. In one exemplary
embodiment, the pitch of the roof may be approximately a 10 mm to
20 mm drop per meter length (1/8'' to 1/4'' drop per foot length).
However, the pitch of the roof is typically a result of the space
available in the top of the moment frame. FIG. 11 depicts an
embodiment of a moment module 1110 using a double-pitch roof with
the highest point in the center of the moment module. Pitched roof
elements may be made using composite panels, metal sheet or
wood.
[0077] In one embodiment, the roof may be made from stamped
corrugated steel sheet and then covered with a polyisocyanurate
(PIR) extruded foam board. The PIR board may then be covered with
an ethylene propylene diene (EPDM) M-class synthetic rubber. Other
embodiments may include alternative materials for insulating and
waterproofing roofs. In some embodiments, support for the pitched
roof may be provided by ledger elements (described below) or cross
beam support (not shown). Pitched-roof moment modules 1010 and 1110
may be used for a single story building or as the top floor of a
multi-story building.
[0078] In an alternate embodiment, the roof may be constructed
using stamped corrugated steel sheet. The steel sheet may be welded
along the seams to provide a waterproof barrier. The steel sheet
may be installed to provide a pitch, as described above. In
alternate embodiments, the steel sheet may be preformed or
installed to form a convex shape. This allows water or other fluids
to drain from the top of the moment module.
[0079] FIG. 12 depicts one embodiment of a roof drainage system. As
shown in FIG. 12, a channel member 1112 may be used to support one
end of the pitched roof. Alternatively, the pitched roof may be
supported by ledger or other frame elements. The portion of the
frame above the roof is left open to allow water to flow without
obstruction. In some embodiments, a beam member 1114 may be used
above the open portion of the frame to increase the strength of the
top of the moment frame. In alternative embodiments, the beam of
the frame may have holes or slots that also allow for fluids to
drain from the top of the moment module.
[0080] FIG. 13 depicts a walled moment module 1310. In some
embodiments, the walls 1320 of the moment module 1310 may include a
set of one or more composite panels. Similar to the panels used
floor of the moment module 100 in FIG. 2, the wall panels may
include interlocking panel joint elements. See also FIG. 3 for an
example of an interlocking panel joint. In alternative embodiments,
the side panels may be made from metal sheet. For example, a single
metal sheet or several metal sheets may be attached to portions of
the moment frame beam. Alternatively, side walls may also be
constructed from traditional wall materials, including metal studs,
sheet rock and insulation.
[0081] In some embodiments, a rubberized sheet may be included in
the side wall installation to provide a water-tight barrier. In
some embodiments, the side walls are installed only for shipping
and are removed before the moment module is assembled into a
building structure. In other embodiments, the panels are installed
as permanent structural components of the frame.
3. Moment Module, Composite Panel Construction
[0082] As described above, moment modules may use various forms of
a composite panel to provide the floor, ceiling, walls or roofing
of a building structure. FIGS. 14A to 14H depict various views of
an exemplary composite panel 220. FIGS. 15A to 15H depict an
alternate composite panel 250 that provides an end cap 262 with a
flanged portion for mounting.
[0083] As shown in FIG. 14F, the composite panel 220 includes a
frame 230, a core element 222 and two face sheets 224. The core
element 222 is encased in an outer skin. In particular, the core
element 222 is bonded to each of the two face sheets 224. In one
preferred embodiment, the core element 222 is made of foam. For
example, the core element 222 can be an extruded polystyrene foam,
such as an extruded polystyrene Type VI foam plastic board with a
nominal density of 29 kg/m.sup.3 (2.0 lb/f.sup.3). It should be
noted, however, that the core element 222 can be made from various
materials, including, without limitation, cellular honeycomb cores
of various materials such as aramid fiber and resin impregnated
paper, foam cores such as polyurethane or polystyrene (both EPS and
XPS).
[0084] The core element 222 can be bonded to the two face sheets
224 using an adhesive, such as a Type II, Class 2, adhesive. For
example, the core element 222 can be bonded to the two face sheets
224 using a polyurethane adhesive. It should be noted, however,
that various types of adhesives may be used.
[0085] In one exemplary embodiment, the adhesive is applied to the
face sheets 224, such as by spraying the adhesive onto the face
sheets. The face sheets 224 with the adhesive applied are then
pressed against the core element 222. This assembly can be heated
under pressure to cure the adhesive. Temperature and curing
conditions may vary according to the adhesive used. It should be
noted that the composite panel can be fabricated using various
fabrication processes to bond the face sheets 224 to the core
element 222.
[0086] In one embodiment, the frame 230 includes two end cap pieces
232 and two interlocking joint pieces 234. As described above, the
interlocking joint pieces 234 may be formed from a metal sheet to
provide a protrusion shape 236 and a channel shape 238. See FIG. 16
for an exemplary embodiment of the profile of an interlocking piece
234. This embodiment of an interlocking joint piece 234 may also be
referred to as a side piece.
[0087] Additionally, two metal flanges may be formed into the
interlocking joint piece 234 so that the flanges can be inserted
into a hem fold on the face sheets 224. This particular embodiment
allows the interlocking joint pieces 234 to be physically connected
to the face sheets 224 without the use of fasteners or welds.
However, in some embodiments, the interlocking joint pieces 234 may
also be spot welded to the face sheets 224. The end cap pieces 232
may then be installed by attaching the flanges of the end cap
pieces 232 to the interlocking joint pieces 234, using threaded
fasteners.
[0088] When fully assembled, the two face sheets 224 are
substantially parallel to each other. Additionally, the two end cap
pieces 232 are substantially perpendicular to the face sheets 224,
and the two interlocking joint pieces 234 are substantially
perpendicular to both the face sheets 224 and the end cap pieces
232. The frame 230 and face sheets 224, together, form the outer
skin of the composite panel. In some embodiments, the frame and
face sheets are made of galvanized steel.
[0089] FIGS. 17A to 17C depict the face sheet 224 used as both the
top and bottom face sheets in the embodiment of the outer skin
depicted in FIGS. 14A to 14H. FIGS. 19A to 19C depict the end cap
232 used as the front and back edge pieces in the embodiment of the
outer skin depicted in FIGS. 14A to 14H. As depicted in FIG. 14E,
in the present embodiment, the end of the metal frame is flush.
[0090] FIGS. 15A to 15H depict various views of another exemplary
composite panel 250. The present exemplary composite panel 250
differs from the exemplary composite panel depicted in FIGS. 14A to
14H in that the end caps 262 are Z-shaped to have a portion that
extends outward from the edge of the frame (see FIGS. 15E and 15H).
The portion of the end cap that extends outward can be used to
support or hang the panel when mounted in a moment module. FIGS.
20A to 20C depict the z-shaped end caps 262 in more detail. Note,
as depicted in FIGS. 21A and 21B, the end caps of the two exemplary
composite panels can be formed from the same blank 2100.
[0091] The top face sheet 266 of the present exemplary composite
panel 250 may also differ from the top face sheet of the exemplary
composite panel 220 depicted in FIGS. 14A to 14H. The top face
sheet of an alternative embodiment of a composite panel is depicted
in more detail in FIGS. 18A to 18C.
[0092] For additional description of composite panels, see U.S.
Pat. No. 6,588,171, which is incorporated by reference in its
entirety for all purposes.
4. Frame and Panel Integration
[0093] As described above, composite panels may be installed in a
moment module using a variety of configurations. In some
embodiments, composite panels 220 are supported in the moment
module frame 210 through the use of ledgers 270. With reference to
FIG. 22, the beams 212 of the moment frame can include ledgers 270
used to support the composite panels 220. The ledger 270 depicted
in FIG. 22 is an angle iron extrusion that is welded to the beam
212 of the moment frame. Alternatively, a ledger may be formed from
any material that provides a shelf for mounting a composite panel
220. For example, the ledger may be formed from sheet metal or
integrated into the beam extrusion profile. As depicted in FIG. 22,
the composite panel 220 can be attached to the ledgers 270 using
threaded fasteners 272. For example, the threaded fastener may be a
self-drilling, self-tapping threaded screw fastener. With reference
to FIG. 23, a beam 212 without a ledger is depicted. In the
embodiment illustrated in FIG. 23, the composite panel 220 is
attached to the top of the beam using a threaded fastener 272.
[0094] It should be noted, however, that the composite panel can be
attached to the moment frame using various means. For example, some
embodiments of the composite panel may include an outwardly
extended flange formed from the end cap piece of the composite
panel frame. See FIGS. 15A to 15H, for examples of a z-shaped end
cap 262. In some embodiments, the flange of the end cap can be
secured to the moment frame using metal fasteners.
[0095] FIGS. 24 to 26 depict exemplary embodiments of the use of
ledgers in a moment frame. FIGS. 24A and 24B depict a detail and
elevation view of a ledger element used to support a composite
panel installed in the floor of the moment frame. In one
embodiment, the ledger is welded to the frame elements as shown in
FIG. 24A.
[0096] In FIGS. 25 and 26, a hollow structural section (HSS) is
used to form the ledger element. FIGS. 25A and 25B depict an
embodiment of a type-T moment module 810 using ledger elements in
the top of the moment frame. FIGS. 26A and 26B depict an embodiment
of a type-U moment module 910 using ledger elements in the top of
the moment frame.
6. Modular Building Structures
[0097] A complete building structure can be designed and built
using variations of the moment module embodiments described above.
Building moment modules may be fabricated off-site in accordance
with the final building specifications and then shipped to the
construction site for assembly. Alternatively, the moment modules
may be customized once they arrive at the building site or after
they have been integrated into the building structure.
[0098] FIGS. 27A and 27B depict a detail view of four moment
modules joined at their respective corners. FIG. 27A depicts a
corner connection at the corner of the frame of four moment modules
without composite panels. In some embodiments, the top and bottom
corner elements 216, 218 may be used to support the main weight of
the moment module frame. In some embodiments, the top and bottom
corner elements are upper and lower ISO corner castings,
respectively. In other embodiments, the weight of the moment module
frame may be distributed along frame members. Moment modules may be
joined by welding the portions of the frame that are adjacent to
other moment module frame members. For example, a weld may be
placed on each of the meeting edges of the four corner elements
216, 218. In alternative embodiments, a connecting plate or other
connecting hardware may be used to join the corners of the frame.
For example, in some embodiments, an ISO attachment bridge clamp
can be used to tie the moment modules together.
[0099] FIG. 27B depicts a corner connection with the composite
panels of the moment modules installed. As can be seen in FIG. 27B,
a space is left between the composite panel of a lower moment
module, which would form the ceiling of the lower moment module,
and the composite panel of an upper moment module, which would form
the floor of the upper moment module. As discussed earlier, this
space can be used to run wires, plumbing, duct-work, etc.
[0100] FIGS. 28A to 28F depict structural elements of an exemplary
12 moment module building. FIG. 28A depicts a building without
external walls or facing material. FIG. 28B depicts a building
without ceiling or roof elements. FIGS. 28C and 28D depict moment
modules assembled together to form three separate building floors
with an open span (i.e., no internal supporting columns).
[0101] FIG. 28E depicts an embodiment of a single building level
2800 using 12 moment modules 100. FIG. 28E illustrates how moment
modules 100 can be used with different wall configurations to
provide an enclosed space. For example, exterior walls 2810 can be
used to provide a barrier between the interior of the building
floor and outside weather or environmental elements. The exterior
walls 2810 may include windows, doors, or other traditional design
features. The external walls 2810 may also incorporate a protective
facing material, such as vinyl siding, stucco or brick.
Alternatively, the external walls 2810 may be wood, metal or
composite and provide for the mounting of protective facing
materials or facade. The building level 2800 may also incorporate
internal walls 2820 used to partition off space in the level or
create separate rooms. Note that it is not necessary for these
exterior walls 2810 or interior walls 2820 to provide structural or
load-bearing support to the building level 2800. For example,
several of the moment modules 100 have an open span and do not
require additional vertical support from walls or partitions.
[0102] FIG. 28F depicts an alternative embodiment of a building
floor 2850 including individual rooms 2860 and connecting hallway
2870. Because the interior walls are not needed for structural
support, the interior space of a building floor can be reconfigured
or adapted to provide for a flexible floor design layout.
[0103] The building structures, illustrated in FIGS. 28A to 28F,
are merely exemplary embodiments that illustrate the use of a
modular moment frame as a structural element in a building
structure. Alternative embodiments may arrange moment modules in
different configurations or incorporate moment modules with other
known construction elements.
[0104] FIG. 29 depicts moment modules 2920, 2930, and 2940 as
structural elements in a multi-story building 2910. In this
configuration, lower moment modules 2920 support the weight of
upper moment modules 2930 and 2940. Because the lower moment
modules 2920 support a larger load, the lower moment modules 2920
may be constructed using different materials or components than the
upper moment modules 2930 and 2940. For example, the vertical
column or horizontal beam members of the lower moment modules may
be larger and, therefore, able to support the additional
weight.
[0105] FIGS. 30A to 30C depict various examples of a moment module
100 used in different sized building structures. As discussed
above, the components used in each of the moment modules may vary
depending on the loading conditions of the overall building
structure. For example, moment modules located on the lower levels
or on the outside of the structure may be designed to provide
increased load-carrying capabilities.
[0106] FIGS. 30A to 30C further illustrate how the top panels of a
lower moment module can be left open to create a higher ceiling
height for a particular story. Alternatively, the panels of the
bottom of an upper moment module can be left open to create
additional ceiling height.
* * * * *