U.S. patent application number 12/571079 was filed with the patent office on 2010-04-01 for modular building system.
Invention is credited to Victoria Lyons, Kitt Samuel.
Application Number | 20100077683 12/571079 |
Document ID | / |
Family ID | 42055909 |
Filed Date | 2010-04-01 |
United States Patent
Application |
20100077683 |
Kind Code |
A1 |
Lyons; Victoria ; et
al. |
April 1, 2010 |
Modular Building System
Abstract
A modular building system for configuring a building structure
includes foundation units, a plurality of wall panels, a plurality
of wall joints and a roof unit. The foundation units are retained
by an anchoring member or ballast contained in the units. The
foundation units and wall panels are detachably attached as the
engaging members and the complementary engaging members engage to
each other and create a space with a top opening. Adjacent wall
panels are attached by a plurality of wall joints. The roof unit
comprises roof panels and joints engage with one another and with
wall panels for covering the top opening of the building
structure.
Inventors: |
Lyons; Victoria; (Garfield
Heights, OH) ; Samuel; Kitt; (Garfield Heights,
OH) |
Correspondence
Address: |
JAY M. SCHLOFF
6960 Orchard Lake Road, Suite 315
West Bloomfield
MI
48322
US
|
Family ID: |
42055909 |
Appl. No.: |
12/571079 |
Filed: |
September 30, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61101295 |
Sep 30, 2008 |
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Current U.S.
Class: |
52/274 |
Current CPC
Class: |
E04B 1/34315 20130101;
E02D 27/02 20130101 |
Class at
Publication: |
52/274 |
International
Class: |
E02D 27/01 20060101
E02D027/01 |
Claims
1. A modular building system for configuring a building structure,
the modular building system comprising: at least one foundation
unit, said foundation unit comprising a base and an at least one
wall extending upwardly from said base at a periphery of the base
of said unit, said wall including a channel and a shelf therein,
and said foundation unit further comprising at least one aperture
disposed on a top side of the at least one wall thereof; a
plurality of wall panels each of the plurality of wall panels
having engagement features thereon, which engagement features
permit removable attachment of each wall panel of the plurality of
panels to a channel of a foundation unit of at least one foundation
unit, and which engagement features further permit removable
attachment of each wall panel of the plurality of panels to a wall
joint of the modular building system; a plurality of wall joints,
said wall joints comprising engagement features thereon, which
engagement features permit removable attachment to at least one
foundation unit, at least one panel, and a roof unit; and a roof
unit, said roof unit comprising a plurality of roof panels and a
plurality of roof joints, wherein said roof joints attach to said
roof panels and connect the roof panels of the plurality of roof
panels to one another, said plurality of roof panels further
comprising engagement features, which engagement features
facilitate attachment of said panels to said wall panels of a
modular building system, and said plurality of roof joints further
comprising engagement features, which engagement features
facilitate attachment of said joints to at least one wall joint of
a modular building system.
2. The modular building system of claim 1, the system further
comprising at least one floor panel, said floor panel comprising a
substantially planar unit with a first face and a second face with
engagement features disposed on the second face thereof that permit
secure attachment of said floor panel to a shelf of a foundation
unit of the modular building system.
3. The foundation unit of claim 1, wherein the base of said
foundation unit further comprises at least one aperture thereon,
which at least one aperture may accept an anchoring member
therethrough, for securing the foundation unit to a surface.
4. The foundation unit of claim 3, wherein said anchoring member
comprises one of an elongate stake and an elongate shaft.
5. The foundation unit of claim 1, wherein said unit comprises a
plurality of walls extending upwardly from the base of said unit,
which plurality of walls form a cavity within said unit, and within
which cavity a container of ballast may be placed.
6. The plurality of wall panels of claim 1, each of which wall
panel of the plurality of wall panels further comprises at least
one channel disposed on a face thereof, and which panels may
further comprise a plurality of apertures that are disposed through
said panel substantially parallel and adjacent to said channel, and
at least one insulating member disposed on at least one side of
each panel of the plurality of panels.
7. The plurality of wall joints of claim 1, wherein the engagement
features of the at least one wall joint of the plurality of wall
joints comprises an elongate quadrilateral shaft with a first end
and a second end, and a first channel and a second channel disposed
on the exterior of said shaft, an aperture at the first end of said
shaft, and a foundation tooth at the second end of said shaft,
wherein said first channel is configured to receive and securely
retain a side of a wall panel, and wherein said second channel is
configured to receive and securely retain a wall joint extension;
wherein said aperture is configured to receive and securely retain
engagement features of at least one roof joint; and wherein said
foundation tooth is configured to be received in and securely
retained by an aperture disposed on a top side of a foundation
unit.
8. The roof unit of claim 1, wherein each roof panel of said
plurality of roof panels comprises a substantially planar
triangular unit, and wherein the engagement features of said panels
comprise a tooth disposed along each side of the triangle of the
triangular unit, and wherein each roof joint of the plurality of
roof joints comprises a substantially flat elongate member that has
as a length dimension that corresponds to a length dimension of the
side of the roof panel to which a roof joint is attached, and each
roof joint comprises a groove as an engagement feature for secure
attachment to the tooth of a roof panel; and wherein said roof unit
further comprises a roof apex cap that may receive a portion of
each roof joint of the plurality of roof joints and a portion of
each roof panel of the plurality of roof panels for securing said
joints and panels at a central point.
9. The roof panel of claim 8, said roof panel further comprising a
bar that is disposed on an underside of said panel along a side of
said panel that is proximate to a wall panel of a modular building,
which bar comprises a pair of prongs that extend over a side of a
wall panel onto the at least one channel of a wall panel for
removable attachment of a roof panel to a wall panel.
10. The roof joint of claim 8, wherein said joint further comprises
at least one roof joint tooth and at least one roof joint stay,
wherein said roof joint tooth comprises a square-shaped flange that
extends away from an underside of a roof joint at location on said
roof joint that corresponds to a wall joint against which a roof
joint may be disposed, and wherein said roof joint tooth may be
received in an aperture of a first end of a wall joint, wherein
said roof joint tooth further comprises at least one aperture
therein, which at least one aperture may receive a pin therethrough
for further securing the tooth and roof joint within a wall joint
or to the building structure; wherein said at least one roof joint
stay comprises a protuberance that extends away from an underside
of said roof joint, which at least one roof joint stay may be so
position on said underside that, when a roof joint is position in
proximity to a wall joint, the at least one roof joint stay is
immediately adjacent to and conforms to the exterior of a shaft of
a wall joint to which the roof joint is proximate.
11. The modular building system of claim 1, the system further
comprising at least one wall joint extension, said wall joint
extension comprising s substantially elongate unit, which unit may
be received in a foundation unit in proximity to a wall joint that
is also received in a foundation unit, and which wall joint may be
adjacent to a wall panel and may extend along a dimension of said
wall panel for providing support to the wall panel of a building
structure.
12. The foundation unit of claim 5, wherein said walls of said
foundation unit comprise a plurality of apertures extending
perpendicularly through said walls, which apertures may, when a
plurality of foundation units are disposed against one another,
receive pins that may extend from the plurality of apertures of one
foundation unit into the plurality of apertures of another
foundation unit for securely retaining each of the foundation units
in a desired position or configuration.
13. The foundation unit of claim 1, wherein said walls of said
foundation unit comprise a plurality of apertures extending
parallely through said walls, which apertures may, when a plurality
of foundation units are disposed against one another, receive pins
that may extend from the plurality of apertures of one foundation
unit into the plurality of apertures of another foundation unit for
securely retaining each of the foundation units in a desired
position or configuration.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present disclosure claims priority under 35 United
States Code, Section 119 on the U.S. Provisional Patent Application
No. 61/101,295 filed on Sep. 30, 2008, the disclosure of which is
incorporated by reference.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to modular buildings, and
more particularly, to structural elements for use in construction
of the modular buildings.
BACKGROUND OF THE DISCLOSURE
[0003] The building construction field is generally labor and cost
intensive. Construction of a building requires involvement of a
considerable amount of time. To reduce the factors such as labor,
cost and time involvement in the construction of the building,
prefabrication systems provide a potential solution. A typical
prefabrication system involves prefabricated structures that are
erected together to form a building structure.
[0004] Existing prefabrication systems fall into two major
categories, namely, wood and aluminum frame prefabrication systems,
and a concrete prefabrication system. The wood and aluminum frame
prefabrication systems are limited to low density suburban housing,
where ground conditions are stable and dry. The wood and aluminum
frame prefabrication systems are not suitable for those areas where
the ground conditions are erosive and/or wet. These prefabrication
systems involve wood and aluminum frame structures and a foundation
on which a building structure is formed (by erecting the wood and
the aluminum frame structures thereon.) The wood and aluminum frame
structures and the foundation are generally lightweight.
[0005] Where the ground conditions are erosive and wet, a
lightweight foundation of such a building structure may not
withstand such conditions, and the structure may collapse. A
concrete prefabrication system may be more appropriate for these
conditions as well as urban settings due to fire and structural
safety requirements.
[0006] All of these prefabrication systems have not been exploited
to a great extent. More specifically, such systems are exploited in
commercial construction sectors of industry, but in the case of
residential construction, their use is very limited. Most of the
prefabrication systems include structural systems such as walls and
floors, which do not accommodate particular architectural design
needs of individual users. In addition to not being user or market
oriented to any substantial degree, these prefabrication systems
tend to be costly, require expensive erection and dismantling cost.
Accordingly, such prefabrication systems are unsuitable for
applications in both commercial and residential construction
sectors.
[0007] Apart from the above, building structures made by such
prefabricated structures suffer from several disadvantages, such as
cracking due to inclement weather conditions, which result in leaks
and other structural damages. Further, inadequate and ineffective
insulation to noise, heat and cold is one of the major problems in
such building structures. Also, existing designs of such building
structures are generally of a temporary nature and may not be
easily customized to adapt to varying size and layout requirements
of different building locations.
[0008] Furthermore, the portability of such prefabricated
structures can be another problem because of their weight,
complexity of structure and the danger of rupture of the
prefabricated structures while in transport. These structures are
often required in areas where accommodation is needed in an
emergency situation or on a temporary basis, such as in natural
disasters area, refugee camps and military bases. Oftentimes, such
prefabricated structures need to be rapidly transported and erected
to provide emergency habitable structures within a required time.
Such existing prefabricated structures may not be easily and
quickly erected despite these situational demands and
requirements.
[0009] Accordingly, there is a need for prefabricated structures
that can be used in dry as well as in wet and erosive ground
conditions. Further, there is a need for all-purpose prefabricated
structures that can be exploited by both the residential and
commercial construction sectors of industry. Furthermore, there is
a need for prefabricated structures that may be easily erected and
dismantled. The prefabricated structures should also be
reconfigurable to meet requirements of changes in size or place of
a building structure, and should also meet requirements depending
on need of long-term or permanent applications. The prefabricated
structures should also be readily transportable. Moreover, the
prefabricated structures should further be capable of withstanding
poor weather conditions and of providing insulation to noise, heat
and cold.
SUMMARY OF THE DISCLOSURE
[0010] In view of the foregoing disadvantages inherent in the prior
art, the general purpose of the present disclosure is to provide
prefabricated building structures (hereinafter "building
structures" or "buildings") such as a modular building for
configuring a building structure that is configured to include all
advantages of the prior art, and to overcome the drawbacks inherent
therein.
[0011] An object of the present disclosure is to provide a modular
building system that may be utilized in providing residential,
commercial and emergency accommodations, in areas such as coastal
areas, suburban housing areas and urban areas. Further, the modular
building system may be utilized and erected independent of the
nature of the ground or terrain on which it is erected.
[0012] Another object of the present disclosure is to provide a
modular building system that may be easily erected and dismantled,
and may be customizable to meet changing requirements in size and
needs of long-term or permanent applications of building, or
location of the building.
[0013] Yet another object of the present disclosure is to provide a
modular building system that may be able to withstand poor weather
conditions and may provide insulation from noise, heat and
cold.
[0014] Still another object of the present disclosure is to provide
a modular building system that may be readily transportable.
[0015] To achieve the above objects, in an aspect of the present
disclosure, a modular building system for configuring a building
structure is provided. The modular building system comprises at
least one foundation unit, a plurality of wall panels, a plurality
of wall joints and a roof unit. The foundation unit has a plurality
of engaging members. Further, each of the plurality of wall joints
has a plurality of complementary engaging members on a bottom
portion thereof. The complementary engaging members enable the wall
joints to be detachably attached to the foundation unit by engaging
with the engaging members, which wall joints may also secure the
plurality of wall panels to the structure, and particularly, to the
foundation unit. More particularly, each of the plurality of wall
joints extends vertically from a top surface of a foundation unit,
and between at least two adjacent wall members of the plurality of
wall members for configuring a detachable attachment therebetween.
The attachment of the wall panels and the foundation unit configure
a space therebetween above the foundation member with a top
opening. More particularly, each of the plurality of wall joints
extends vertically from a top surface of a foundation unit, and
between at least two adjacent wall members of the plurality of wall
members for configuring a detachable attachment therebetween.
Further, roofing unit may be comprised of a plurality of roof
panels, which panels may have engaging members on edges thereof for
detachable engagement with complementary engaging members of a
plurality of roofing joints, which roof joints can be disposed
between two roof panels. The roof panels may be disposed with
respect to one another to form a peak, which peak may be crowned or
covered by a cap. The roof panels, when so connected and disposed,
may provide for covering the top opening of a building to configure
the building structure.
[0016] The foundation unit may further comprise at least one
securement component for stabilizing and holding the foundation in
a desired place and position. In an embodiment, the securement
component may comprise an at least one aperture, through which an
anchoring member, such as a stake or shaft, may be driven, such
that the anchoring member may be situated beneath the surface on
which the building is erected, in order to hold the foundation unit
in a desired place or position. In another embodiment, at least one
securement component may comprise a container, which container may
be inserted into or integrated within a foundation unit and which
container may receive ballast (such as sand, gravel, and the like)
therein to retain the foundation unit in a desired place or
position.
[0017] In an embodiment, foundation units may further comprise
floor panels, which panels may be disposed on a top side of said
units to form a surface on which a user may place items or may walk
or sit thereon while in the interior of the building. Said floor
panels may rest on shelves and may be flush with wall panels in the
foundation units.
[0018] These together with the other aspects of the present
disclosure, along with the various feature of novelty that
characterized the present disclosure, are pointed out with
particularity in the claims annexed hereto and form a part of the
present disclosure. For a better understanding of the present
disclosure, its operating advantages, and the specified object
attained by its uses, reference should be made to the accompanying
drawings and descriptive matter in which there are illustrated
exemplary embodiments of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The advantages and features of the present disclosure will
become better understood with reference to the following detailed
description and claims taken in conjunction with the accompanying
drawings, wherein like elements are identified with like symbols,
and in which:
[0020] FIG. 1 illustrates an end view of a corner wall joint, wall
panels, and wall joint extensions of a modular building system, in
accordance with an exemplary embodiment of the present
disclosure.
[0021] FIG. 2 shows a disassembled view of a corner wall joint and
wall joint extensions of a modular building system, in accordance
with an exemplary embodiment of the present disclosure.
[0022] FIG. 3 shows a wall joint of a modular building system, in
accordance with an exemplary embodiment of the present
disclosure.
[0023] FIG. 4 shows an end view of a wall joint, wall panels, and
wall joint extensions of a modular building system, in accordance
with an exemplary embodiment of the present disclosure.
[0024] FIG. 5 shows a wall panel of a modular building system, in
accordance with an exemplary embodiment of the present
disclosure
[0025] FIG. 6 shows an overhead view of a foundation unit of a
modular building system, in accordance with an exemplary embodiment
of the present disclosure.
[0026] FIG. 7 shows a sectional view of a foundation unit of a
modular building system, in accordance with an exemplary embodiment
of the present disclosure.
[0027] FIG. 8 shows a sectional view of a roof unit of a modular
building system, in accordance with an exemplary embodiment of the
present disclosure.
[0028] FIG. 9 shows a side view of a roof panel and wall panel of a
modular building system in accordance with an exemplary embodiment
of the present disclosure.
[0029] FIG. 10 shows the connection of roof joints and roof panels
of a modular building system, in accordance with an exemplary
embodiment of the present disclosure.
[0030] FIG. 11 shows a roof joint tooth and roof joint stays of a
modular building system, in accordance with an exemplary embodiment
of the present disclosure.
[0031] FIG. 12A shows a roof apex cap of a modular building system,
in accordance with an exemplary embodiment of the present
disclosure.
[0032] FIG. 12B shows roof joints, roof joint teeth, and roof joint
stays of a modular building system, in accordance with an exemplary
embodiment of the present disclosure, and
[0033] FIG. 13 shows a modular building structure of a modular
building system in an assembled state, in accordance with an
exemplary embodiment of the present disclosure.
[0034] Like reference numerals refer to like parts throughout the
description of several views of the drawings.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0035] For a thorough understanding of the present disclosure,
reference is to be made to the following detailed description,
including the appended claims, in connection with the
above-described drawings. Although the present disclosure is
described in connection with exemplary embodiments, the present
disclosure is not intended to be limited to the specific forms set
forth herein. It is understood that various omissions and
substitutions of equivalents are contemplated as circumstances may
suggest or render expedient, but these are intended to cover the
application or implementation without departing from the spirit or
scope of the claims of the present disclosure. Also, it is to be
understood that the phraseology and terminology used herein is for
the purpose of description and should not be regarded as
limiting.
[0036] The term "first", "second", "top", "bottom", "inner",
"outer" and the like, herein do not denote any order, quantity or
importance, but rather are used to distinguish one element from
another, and the terms "a" and "an" herein do not denote a
limitation of quantity, but rather denote the presence of at least
one of the referenced item.
[0037] The present disclosure provides a modular building system
for configuring a building structure 1000 for residential,
commercial and emergency accommodation purposes. The modular
building system comprises a plurality of modular structures, such
as at least one foundation unit 100, a plurality of wall panels
200, a plurality of wall joints 300, and a roof unit 400 that are
assembled together to configure the building structure that may be
used as residential and commercial purpose in case of emergency as
well as a permanent shelter. Further, the building structure 1000
may be disassembled back into the plurality of modular structures,
and may be transported to required construction locations.
[0038] An exemplary embodiment of a wall joint 300 of the modular
building system is shown in FIG. 1 and FIG. 2. In this embodiment a
wall joint of the modular building system comprises a corner wall
joint 301 for joining a plurality of wall panels, and for receiving
at least one roof joint. The wall joint 301 comprises a
substantially elongate quadrilateral shaft 305, the height of which
shaft may be substantially the same as the height of the wall panel
or panels that attach to the wall joint. On at least one side of
the elongate shaft of the wall joint is a first channel 310 and a
second channel 320. The first and second channels 310 and 320 are
formed from cut-outs made in the exterior of the shaft. The
channels may be of varying shapes, and in an embodiment, may be so
formed to permit engagement and secured attachment of a wall panel,
wall joint extension 330, or other component, such that the
attached component may be securely fastened to the wall joint. FIG.
1 shows a corner wall joint 301, wall panels 200, and wall joint
extensions 330 in an assembled state. It will be apparent that more
than one side of the shaft may include such channels, and in and
embodiment, the sides that include such channels may be sides that
are perpendicular to one another, such that the wall joint and wall
panels attached thereto will form a corner of the building. In
another embodiment, where the channels 310 and 320 are disposed on
sides of the shaft that are parallel to one another, the wall joint
300 and wall panels 200 that are attached thereto may form an
extended wall section or face of the building, which embodiment
will be described in further detail below.
[0039] In yet another embodiment, and for erecting other
configurations of wall panels 200, various other wall joints 300,
such as a triple wall joint, a quadruple wall joint, and the like
may be used. As described above, and as shown in FIGS. 3 and 4, two
wall panels 200 may be connected in a straight line using a wall
joint 302 with channels disposed on opposite sides of the wall
joint shaft 305. It will be apparent to one skilled in the art that
a triple wall joint is capable of receiving three wall panels.
Similarly, a quadruple wall joint is capable of receiving four wall
panels. It will be apparent to one skilled in the art that a
building structure of the present system may be assembled in a
variety of configurations, through the use of the various wall
joints, for example, to configure building structures with varying
floor plans and layouts to meet a particular need or preference of
a user
[0040] In an embodiment, the shaft 305 of the wall joint 300
further comprises a first end 306 and a second end 307, with the
first end 306 disposed proximate to the surface on which the
building system is erected (when the building system is in a
constructed state), and the second end 307 disposed distal to the
surface in such a state. The second end may include an aperture
307a for receiving a roof joint, and more particularly, a flange of
a roof joint. Proximate to the second end may be a plurality of
apertures in the sides of the shaft 307b, which apertures may be
perpendicular to the faces of the sides. Said apertures 307b may
correspond to apertures in a roof panel or roof joint (to be
described in further detail below), such that, when the roof panel
or roof joint is attached to the second end 307 of the shaft 305 of
the wall joint 302, a pin may be inserted through each of the
apertures on the sides of the shaft and through a corresponding
aperture on the roof panel or roof joint to further secure the roof
panel or roof joint to the wall joint.
[0041] Referring further to FIG. 3 and FIG. 4 another view of a
wall joint 300 is shown, in an embodiment where the channels are
disposed on sides of the shaft that are parallel to one another,
and the wall joint 300 and wall panels 200 that are attached
thereto may form an extended wall section or face of the building,
In this embodiment, the wall joint 302 further comprises flanges
322 extending away in opposite directions away from each other and
from the shaft 305 of said joint, which flanges 322, when the wall
joint is in an installed configuration in a modular building, are
disposed on the exterior of said building. In an embodiment, the
shaft 305 of the wall joint further comprises a first end 306 and a
second end 307, with the first end disposed proximate to the
surface on which the building system is erected (when the building
system is in a constructed state), and the second end disposed
distal to the surface in such a state. The second end may include
at least one aperture 307a for receiving a roof joint, and more
particularly, a flange of a roof joint. Proximate to the second end
may be a plurality of apertures 307b in the sides of the shaft.
Said apertures 307b may correspond to apertures in a roof panel or
roof joint (to be described in further detail below), such that,
when the roof panel or roof joint is attached to the second end 307
of the shaft 305 of the wall joint 302, a pin may be inserted
through each of the apertures 307b on the sides of the shaft 305
and through a corresponding aperture on the roof panel or roof
joint to further secure the roof panel or roof joint to the wall
joint 302.
[0042] Referring now to FIG. 5, a wall panel 200 is shown. In an
embodiment, a wall panel of the modular building system comprises a
substantially planar unit that is configured to form a barrier
between the interior and exterior of a building. The wall panel 200
will be preferably in the form of a quadrilateral, with a first
side 201 configured to be disposed adjacent to an area of a
foundation unit to form a corner between the wall panel and the
foundation unit within the building structure. A second side 202 of
the wall panel may be disposed adjacent to a roof panel to form a
corner between the wall panel and the roof panel within the
building. The second side 202 of the wall panels may further
comprise a channel 208 disposed in proximity to the second side 202
on a face of said panel, which channel 208 may be capable of
receiving a portion of a roof panel, and more specifically, a roof
coupling bar that protrudes from an interior side of a roof panel,
for facilitating the attachment of the roof panel to the wall
panel. Proximate to the second side of the wall panel may be a
plurality of roof pin apertures 212 that configure hollow openings
that run from a third side 203 to a fourth side 204 of the wall
panel, which apertures 212 may receive pins (to be described
further below) for fastening a roof panel to a wall panel. At least
one of the four sides of the wall panel may further include an
insulating member attached thereto, which insulating member (not
shown) may prevent air and/or water from entering the building at a
point where a wall panel is disposed against a roof panel, a
foundation member, or another wall panel, for example. The
insulating member may of a sponge, rubber, or other similar pliable
material.
[0043] Referring now to FIG. 6, a top view a foundation unit 100 is
shown, in accordance with an embodiment of the present disclosure.
The foundation unit 100 comprises a base 110 and an at least one
wall 120 extending upwardly therefrom at a periphery of the base of
the unit. The at least one wall is such that it extends inwardly
from the periphery of the base a limited distance such that at
least a portion of the base remains exposed at an interior of the
foundation unit 100.
[0044] In an embodiment, the base 110 of the foundation unit 100
may further comprise a plurality of apertures 115 disposed thereon,
which apertures 115 are capable of receiving an anchoring member
(not shown) for stabilizing and holding the foundation unit in a
desired place and position. In an embodiment, an anchoring member,
such as a stake or shaft, may be driven, such that the anchoring
member may be situated beneath the surface on which the building is
erected, in order to hold the foundation unit in a desired place or
position. The anchoring member may be made of materials including,
but not limited to, high density polyethylene (HDPE). In an
embodiment of the present disclosure, the anchoring member includes
a head area and a tail area. The head area may be substantially
thicker than the tail area, and may include a tapping cap at a top
portion thereof. The anchoring member may be inserted into an
aperture by using a mallet (not shown) or a pin awl (not shown)
until an at least a portion of the tail area is inserted into the
ground.
[0045] In another embodiment, the base 110 of the foundation unit
further comprises a cavity that is formed by the disposition of
walls 120 extending upwardly from each side of the foundation unit
100. In such an embodiment, a user may place a container (not
shown) in said cavity, which container may be filled with ballast
material such as gravel, sand, water (held within in a bladder, for
example), and the like, and which container may secure the building
system to the ground or surface on which the building system is
erected, to provide stabilization to the system in its erected
state.
[0046] Referring now to FIG. 7, a partial view of the at least one
wall 122 of the walls 120 of the foundation unit 100 is shown. The
wall 122 may be of sufficient width, when measured from the
exterior side of the foundation unit 100, to include a channel 130
therein, as well as a shelf 140 formed at the edge of the wall that
is distal to the exterior side of the foundation unit 100. The
channel 130 so formed may be of an appropriate width and depth to
securely receive at least one of a side of a wall panel 200 and at
least one wall joint extension 330, and the channel 130 may include
an indentation 132 therein to receive further the insulating member
disposed on a side of the wall panel 200. Extending further inward
from the exterior side of the foundation unit 100, the wall 120 of
the foundation unit 100 may include a shelf 140 that is formed from
a section that is cut out of the wall. More specifically, the shelf
140 may be disposed at the termination of the wall 120 that is
proximate to the interior of the foundation unit 100. The shelf 140
may include a substantially planar region 142 that extends away
from and beneath the top side of the at least one wall 120 of the
foundation unit 100. The shelf 140 may support a floor section (to
be described in greater detail below) that may be disposed above
the base 110 of the foundation unit 100. It will be apparent that
the removable attachment of a floor section allows a user to first
secure the foundation unit 100 with an anchoring member or ballast
container as described above before placing the floor section on
the foundation unit 100.
[0047] Referring still to FIG. 7, the foundation unit 100 further
comprises at least one foundation pin aperture 128, which aperture
128 extends along the full dimension of the foundation unit 100 in
a linear direction, which at least one aperture 128 is capable of
receiving a foundation pin, which pin may extend at least along the
full length of the aperture 128. Further, a first foundation unit
100 may be disposed adjacent to a second foundation unit 100 such
that the at least one foundation pin aperture 128 of the first
foundation unit 100 may be disposed in sufficient proximity to the
at least one foundation pin aperture 128 of the second foundation
unit 100, such that a foundation pin of an appropriate length may
be inserted into and span through the corresponding foundation pin
apertures 128 of the two foundation units, in order to facilitate
secure attachment and retention of the two foundation units 100
adjacent to one another.
[0048] Referring again to FIG. 6, the foundation unit 100 may
further comprise at least one aperture 127 for receiving a wall
joint 300 therein, which at least one aperture 127 may be disposed
on a top side of the at least one wall 120 of the foundation unit
100 at a position that facilitates corresponding engagement with a
wall joint 300. Referring to FIGS. 2 and 3 again, a wall joint 300
of the present disclosure further comprises at least one foundation
tooth 350 at a first end 306 end of said wall joint 300, which
tooth 350 may be received in a wall joint aperture 125 or 127 of a
foundation unit 100. The foundation tooth 350 of a wall joint 300
of the present disclosure comprises a protuberance that extends
away from the wall joint 300, the dimensions of which protuberance
correspond to the dimensions of a wall joint aperture 125 or 127 of
a foundation unit 100 such that the insertion of the foundation
tooth 350 into the wall joint aperture 125 or 127 results in a
substantially secure fit of the wall joint 300 to the foundation
unit 100. The tooth 350 may further comprise at least one aperture
therethrough that is capable of receiving a holding pin for
retaining the wall joint 350 within the wall joint aperture 125 or
127.
[0049] Referring again to FIG. 6, in an embodiment, a modular
building 1000 of the modular building system may be formed by
disposing four quadrilateral-shaped foundation units 100 against
one another, with one corner of each unit 100 abutting one corner
of each other unit 100 at a single point. In such an orientation,
the walls 120 of the foundation units 100 may be so disposed that a
wall joint aperture 125 is disposed at each corner of the aggregate
foundation formed by the four foundation units 100. Further in such
an orientation, adjacent foundation units 100 may combine to form a
wall joint aperture 127 at each midpoint of a side of the aggregate
foundation formed by four foundation units. In an embodiment, the
walls 120 of the foundation units 100 that are adjacent to one
another may include corresponding foundation wall apertures 118
therein through which pins or screws may be inserted to facilitate
secure attachment of each of the foundation units 100 to one
another. In an embodiment, a holding pin inserted through said
apertures 118 of a plurality of foundation units will be of
sufficient length to extend through the plurality of foundation
units for providing secure attachment of said foundation units.
[0050] In an embodiment, a floor section (not shown) of a
foundation unit 100 of the present disclosure comprises a
substantially planar component of dimensions that permits secure
attachment and placement of a floor section upon a foundation unit
100. Furthermore, said floor section may have a first side and a
second side such that, when the floor section is placed upon a
foundation unit 100, said first side is distal to the base 110 of
the foundation unit 100 and said second side is proximate to the
base 110 of the foundation unit 100. Said second side of said floor
panel may include complementary configurational features, such as
cut outs, for example, along the periphery of said floor panel,
that facilitate secure engagement with a foundation unit 100, and
particularly, the shelf 140 of the walls 120 of a foundation unit
100.
[0051] Referring now to FIG. 8 and FIG. 9, a partial view of a roof
unit 400 of a modular building system is shown, in an exemplary
embodiment of the present disclosure. The roof unit 400 of the
building system includes at least one roof panel 410, to be
discussed in further detail below, The roof panel 410 of the
building system may optionally extend past the perimeter of the
building structure or wall panels, for example, for providing
overhead shelter beyond the wall panels of the building structure.
On the underside of the roof panel 410 is a roof coupling bar 414,
which roof coupling bar 414 permits a roof panel 410 to attach to a
wall panel 200. The roof coupling bar 414 is disposed substantially
parallel to a side or edge of the roof panel 410 to which it is
attached, and the bar may run along the entire length of the side
or edge of the panel 410 on which it is disposed. The roof coupling
bar 414 is so configured to permit removable secure attachment with
a wall panel 200, and more particularly, with a channel 208 of a
side 202 of wall panel 200. In an embodiment, the roof coupling bar
comprises a pair of prongs that extend over the edge of a side 202
of a wall panel 200 sufficiently far enough to engage, on each face
of a wall panel 200, the channel 208 that is disposed away from the
side 202 of the wall panel 200. The wall panel 200 includes a
plurality of roof pin apertures 416, which apertures 416 may
receive roof holding pins, which pins may be of sufficient length
to extend through a wall panel 200 and roof tooth (discussed in
detail below) for securing a roof panel 410 to a modular
building.
[0052] Referring again to FIG. 8, a sectional view of a roof unit
400 of a modular building system is shown. In an embodiment, the
roof unit 400 of a modular building system comprises a plurality of
roof panels 410, a roof apex cap 420, and a plurality of roof
joints 430. Roof panels 410 are substantially planar triangular
units with engagement members on the edges thereof. In an
embodiment, roof panels 410 may be in the form of isosceles right
triangles. To form a roof unit 400 of a modular building system, a
pair of roof panels 410 may be disposed adjacent to one another
such that the hypotenuse of each panel 410 of the pair of panels
410 is disposed against the other. In such a configuration, a
quadrilateral is formed. The roof unit 400 of a modular building
system may accordingly comprise a plurality of quadrilaterals so
formed, to form a roof unit 400 of an appropriate size and
dimensions to provide for cover of an interior of a modular
building structure.
[0053] Roof joints 430 comprise substantially flat and elongate
members with engagement features along the sides thereof. Said
engagement features permit attachment with complementary engagement
features of roof panels 410. In an embodiment, a roof joint 430 may
be disposed between the hypotenuse of a first roof panel 410 and
the hypotenuse of a second roof panel 410 to secure such roof
panels together. Further, a roof joint 430 may be disposed between
a leg of a first roof panel 410 and a third roof panel 410 to
secure such roof panels together. The engagement features of a roof
joint 430 and roof panel 410 of the present disclosure will be
explained in detail below, in conjunction with FIGS. 10 and 11. In
an embodiment where the plurality of quadrilaterals are so formed
as to create a pitched or sloped roof unit 400 that culminates in a
central high point, the plurality of quadrilaterals formed by a
pair of roof panels 410 may further be secured together at said
central point. A roof apex cap 420 may secure the plurality of
quadrilaterals so formed by covering the common point at which the
plurality of quadrilaterals are proximately disposed. It will be
apparent that the apex cap 420 may be appropriately configured to
accommodate a slope of the roof unit 400 of a modular building
while still maintaining a secure attachment to the roof panels 410
and/or roof joints 430 thereof. When said roof apex cap 420, roof
joints 430, and roof panels 410 are in an assembled state, a roof
unit 400 is configured to provide cover over the interior of the
modular building.
[0054] Referring now to FIG. 10, detailed views of exemplary
engagement features of roof joints 430 and roof panels 410 and are
shown, in accordance with exemplary embodiments of the present
invention. In an embodiment, a roof panel 410 will include a tooth
411, which tooth 411 may engage with a groove 431 of a roof joint
430, for secure attachment of the roof panel 410 and the roof joint
430. The groove or grooves of a center roof joint 430a may be
oriented such that the center roof joint 430a attaches to a first
and a second roof panel 410 to form and maintain a substantially
planar construction. The groove or grooves of a corner roof joint
430b may be oriented such that, when a first and third roof panel
410 are attached to said corner roof joint 430b, an appropriate
transition between the first and third roof panel 410 is achieved
to maintain engagement (not shown) between the first roof panel and
its corresponding wall panel and between the third roof panel and
its corresponding wall panel. Such a corner roof joint 430b may be
utilized to secure roof panels that are attached to wall panels
that form a corner of a modular building.
[0055] FIG. 11 shows detailed views of a roof joint tooth 435 and
of a roof joint stay 436 of a roof joint 430, in accordance with an
embodiment of the present disclosure. A roof joint 430 comprises at
least one roof joint tooth 435 and at least one roof joint stay
436. A roof joint tooth 435 of a roof joint of the present
disclosure comprises a square-shaped flange that extends away from
the underside of a roof joint at a point on the roof joint that is
distal to the roof apex of the building system. The at least one
roof joint stay 436 further comprises at least one aperture 438
extending completely therethrough, which at least one aperture may
accept a holding pin for obtaining secure attachment of the roof
joint to the building structure. The roof joint 430 may further
comprise at least one roof joint stay 436, which stay comprises a
protuberance that extends away from the underside of a roof joint
430. In a preferred embodiment, a roof joint 430 will comprise two
joint stays 436a and 436b, with one stay 436a disposed on one side
of the at least one roof joint tooth 435 along the underside of the
roof joint 430, and the other stay 436b disposed on the other side
of the at least one roof joint tooth 435 along the underside of the
roof joint, such that the at least one roof joint tooth 435 may be
inserted into an aperture 307a on a second end 307 of a wall joint
300, which insertion will provide secure attachment of the at least
one roof joint tooth 435 of the roof joint 430 to a wall joint 300.
Further, the joint stays 436 will be positioned accordingly with
respect to the at least one roof joint tooth 435 and dimensions of
the wall joint 300 such that the joint stays will be securely
disposed against the exterior of the second end 307 of the wall
joint 300.
[0056] Referring now to FIG. 12A, a view of a roof apex cap 420 is
shown. In an embodiment, the apex cap 420 comprises a neck portion
422 immediately underneath the cap, and a flange portion 424
underneath the neck portion. The neck portion 422 may accommodate
the ends of roof panels 410 and/or roof joints 430, with the apex
cap 420 and flange portion being disposed over at least a portion
of the roof joints 430 and/or roof panels 410, such that a
weatherproof seal is created by the roof apex cap 420 between the
side of the roof panels 410 and roof joints 430 that is exposed to
the exterior of the modular building and the side roof panels 410
and roof joints 430 that is exposed to the interior of the modular
building.
[0057] Referring to FIG. 12B, overhead perspective views of roof
joint teeth 435 and roof joint stays 436 are shown, for a center
roof joint 430a and for a corner roof joint 430b. It will be
apparent that the at least one roof tooth 435 and the at least one
roof joint stay 436 of a roof joint 430 may be appropriately
positioned so that the corresponding at least one wall joint
aperture 307a may securely receive the at least one roof joint
tooth 435 and so that the at least one roof joint stay 436 may
securely bracket the wall joint 300 against which it is
disposed.
[0058] Shown in FIG. 13 is a modular building 1000 of a modular
building system in an assembled state. It will be apparent to one
skilled in the art that the wall panels 200 will be formed from
materials that permit a user to make requisite cut-outs for
windows, doors, and the like, and that such cut-outs may accept
such windows, doors, and the like by way of hinges, seals, frames,
and other securement mechanisms known in the art. In an embodiment,
wall panels 200 may comprise a plurality of thin layers of
polypropylene, with a polypropylene honeycomb or lattice formation
between each layer.
[0059] Further regarding the resiliency of the materials used to
construct the components of the modular buildings 1000 of the
modular building system herein, a user may make requisite cuts or
adjustments to permit the connection of plumbing, electrical, or
HVAC systems from an exterior source and to permit installation of
requisite interconnections of such components of such systems
within a building to provide for service of such systems throughout
a modular building.
[0060] The building or building structure 1000 constructed by the
modular building system may be easily dismantled by removing
foundation unit and roof unit holding pins and anchoring members
used in assembling of the building. The disassembled parts such as
the foundation units, the wall panels, the wall joints and the roof
joints and panels and other parts may be easily transported from
one place to another place. Further, based on the particular need,
the size of the building and the number of rooms in the building
may be customized based on using the various components. The
building constructed by the modular building system may be used on
a short-, long-term, or a semi-permanent basis.
[0061] The modular building system of the present disclosure is
advantageous in constructing buildings for both residential and
commercial purposes in suburban housing areas, urban buildings
areas and disaster areas. The modular building system may also be
utilized to construct a building structure in wet or icy ground
conditions. Further, the modular building system may be easily
erected and dismantled.
[0062] Furthermore, the modular building system is capable of
providing insulation against noise, heat and cold, and is capable
of withstanding in inclement weather conditions. Moreover, the
modular building system is easily and readily transportable.
[0063] The foregoing descriptions of specific embodiments of the
present disclosure have been presented for purposes of illustration
and description. They are not intended to be exhaustive or to limit
the present disclosure to the precise forms disclosed, and
obviously many modifications and variations are possible in light
of the above teaching. The embodiments were chosen and described in
order to best explain the principles of the present disclosure and
its practical application, to thereby enable others skilled in the
art to best utilize the present disclosure and various embodiments
with various modifications as are suited to the particular use
contemplated. It is understood that various omission and
substitutions of equivalents are contemplated as circumstance may
suggest or render expedient, but such are intended to cover the
application or implementation without departing from the spirit or
scope of the claims of the present disclosure.
* * * * *