U.S. patent application number 17/032904 was filed with the patent office on 2021-03-04 for systems and methods for manufactured modular construction.
The applicant listed for this patent is MMC-3 Holdings. Invention is credited to Gilbert MEYER, Ethan WONG.
Application Number | 20210062525 17/032904 |
Document ID | / |
Family ID | 1000005107780 |
Filed Date | 2021-03-04 |
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United States Patent
Application |
20210062525 |
Kind Code |
A1 |
MEYER; Gilbert ; et
al. |
March 4, 2021 |
SYSTEMS AND METHODS FOR MANUFACTURED MODULAR CONSTRUCTION
Abstract
Systems, methods, and devices of the various embodiments may
enable manufactured modular construction. The various embodiment
manufactured modular construction systems, methods, and devices may
offer a solution to the housing shortage worldwide that is less
than half the cost of the cost of current modular buildings.
Various embodiments may include interlocking vertical and
horizontal elements. Various embodiments may include a locking
system pulling upper horizontal elements of an embodiment modular
building toward lower horizontal elements and/or a foundation or a
lower floor of the embodiment modular building to thereby lock
vertical elements and vertical panels in place between the upper
horizontal elements and the lower horizontal elements, foundation,
and/or lower floor. In various embodiments, the locking system may
include a shock absorber.
Inventors: |
MEYER; Gilbert; (Richboro,
PA) ; WONG; Ethan; (Richboro, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MMC-3 Holdings |
Richboro |
PA |
US |
|
|
Family ID: |
1000005107780 |
Appl. No.: |
17/032904 |
Filed: |
September 25, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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16556723 |
Aug 30, 2019 |
10787829 |
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17032904 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04H 1/02 20130101; E04H
1/005 20130101 |
International
Class: |
E04H 1/02 20060101
E04H001/02; E04H 1/00 20060101 E04H001/00 |
Claims
1. A modular building, comprising: at least one lower horizontal
element; at least one vertical element configured to form a hollow
central portion; at least one upper horizontal element; and at
least one locking system connecting the lower horizontal element,
the vertical element, and the upper horizontal element together,
wherein the locking system at least partially passes through the
vertical element and is under tension to thereby pull the lower
horizontal element, the vertical element, and the upper horizontal
element together.
2. The modular building of claim 1, further comprising a vertical
panel joined between the lower horizontal element and the upper
horizontal element and joined to the vertical element.
3. The modular building of claim 2, wherein channels are formed
between the vertical panel, the lower horizontal element, the upper
horizontal element, and the vertical element when the vertical
panel, lower horizontal element, upper horizontal element, and
vertical element are joined together.
4. The modular building of claim 3, further comprising a utility or
data connection formed in at least one of the channels.
5. The modular building of claim 4, wherein the vertical element,
the upper horizontal element, or the lower horizontal element are
comprised of fiber reinforced plastic.
6. The modular building of claim 5, wherein the vertical panel
comprises aluminum composite panels with foam sandwiched
therebetween.
7. The modular building of claim 2, wherein the vertical panel
comprises a structural insulated panel.
8. The modular building of claim 2, wherein the locking system
includes a shock absorber.
9. The modular building of claim 8, wherein the shock absorber
comprises a rubber block, spring, or hydraulic system connected to
a lock rod, bar, or cable of the locking system.
10. The modular building of claim 1, further comprising: a roof
support affixed to the upper horizontal element; and at least one
roof panel affixed to the roof support.
11. A method of installing a modular building, comprising: affixing
at least one lower horizontal element to a foundation; sliding a
vertical element configured to form a hollow central portion over a
first raised portion of the lower horizontal element; sliding a
vertical panel over a second raised portion of the lower horizontal
element and over a raised surface element of the vertical element;
sliding an upper horizontal element into the vertical element and
the vertical panel; affixing a locking system between the lower
horizontal element and the upper horizontal element; and tensioning
the locking system to pull the lower horizontal element, the
vertical element, and the upper horizontal element together.
12. The method of claim 11, wherein the vertical panel is a wall
panel, a window panel, or a door panel.
13. The method of claim 11, further comprising: affixing a roof
support to the upper horizontal element; and affixing a roof panel
to the roof support.
14. The method of claim 11, further comprising: affixing a floor
support to the upper horizontal element; affixing a floor portion
to the floor support; and affixing at least one additional lower
horizontal element to the floor support to support a second level
for the modular building.
15. The method of claim 11, wherein affixing the locking system
between the lower horizontal element and the upper horizontal
element comprises affixing the locking system between the lower
horizontal element and the upper horizontal element through the
hollow central portion of the vertical element.
16. The method of claim 11, further comprising affixing an inner
wall to the lower horizontal element such that the locking system
is disposed between the vertical panel and the inner wall.
17. The method of claim 11, wherein the vertical element, the upper
element, or the lower horizontal element are comprised of fiber
reinforced plastic.
18. The method of claim 11, wherein the vertical panel comprises
aluminum composite panels with foam sandwiched therebetween.
19. The method of claim 11, wherein the vertical panel comprises a
structural insulated panel.
20. The method of claim 11, further comprising joining the vertical
element, the upper element, or the lower horizontal element to the
vertical panel without using fasteners.
21. The method of claim 11, wherein tensioning the locking system
to pull the lower horizontal element, the vertical element, and the
upper horizontal element together thereby holds structural elements
of the modular building together without glue or caulk.
22. A modular building, comprising: means for affixing at least one
lower horizontal element to a foundation; means for sliding a
vertical element configured to form a hollow central portion over a
first raised portion of the lower horizontal element; means for
sliding a vertical panel over a second raised portion of the lower
horizontal element and over a raised surface element of the
vertical element; means for sliding an upper horizontal element
into the vertical element and the vertical panel; means for
affixing a locking system between the lower horizontal element and
the upper horizontal element; and means for tensioning the locking
system to pull the lower horizontal element, the vertical element,
and the upper horizontal element together.
23. The modular building of claim 22, further comprising means for
forming channels between the vertical panel, the lower horizontal
element, the upper horizontal element, and the vertical element
when the vertical panel, lower horizontal element, upper horizontal
element, and vertical element are joined together.
24. The modular building of claim 23, further comprising means for
forming a utility or data connection in at least one of the
channels.
25. The modular building of claim 22, further comprising: means for
affixing a roof support to the upper horizontal element; and means
for affixing a roof panel to the roof support.
26. The modular building of claim 22, further comprising: means for
affixing a floor support to the upper horizontal element; means for
affixing a floor portion to the floor support; and means for
affixing at least one additional lower horizontal element to the
floor support to support a second level for the modular
building.
27. The modular building of claim 22, further comprising means for
affixing an inner wall to the lower horizontal element such that
the locking system is disposed between the vertical panel and the
inner wall.
28. The modular building of claim 22, further comprising means for
joining the vertical element, the upper element, or the lower
horizontal element to the vertical panel without using
fasteners.
29. The modular building of claim 22, wherein means for tensioning
the locking system to pull the lower horizontal element, the
vertical element, and the upper horizontal element together hold
structural elements of the modular building together without glue
or caulk.
30. The modular building of claim 22, further comprising means for
shock absorbing connected to the locking system.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of, and claims priority
to, U.S. application Ser. No. 16/556,723 entitled "Systems and
Methods for Manufactured Modular Construction" filed on Aug. 30,
2019, the entire contents of which are incorporated herein by
reference.
SUMMARY
[0002] Systems, methods, and devices of the various embodiments may
enable manufactured modular construction.
[0003] Various embodiments may provide a modular building,
comprising: at least one lower horizontal element; at least one
vertical element configured to form a hollow central portion; at
least one upper horizontal element; and at least one locking system
connecting the lower horizontal element, the vertical element, and
the upper horizontal element together.
[0004] Various embodiments may provide a locking system for a
modular building, comprising: a shock absorber; and a locking
element connected to the shock absorber, wherein the shock absorber
and locking element together connect an upper element of the
modular building to a foundation or a lower horizontal element of
the modular building and pull the upper element toward the
foundation or the lower horizontal element to thereby lock a
vertical element and/or a vertical panel in place between the upper
element and the foundation or the lower horizontal element. In
various embodiments, the upper element may be an upper horizontal
element of the modular building.
[0005] Various embodiments may provide a method of installing a
modular building, comprising: affixing at least one lower
horizontal element to a foundation; sliding a vertical element
configured to form a hollow central portion over a first raised
portion of the lower horizontal element; sliding a vertical panel
over a second raised portion of the lower horizontal element and
over a raised surface element of the vertical element; sliding an
upper horizontal element into the vertical element and the vertical
panel; affixing a locking system between the lower horizontal
element and the upper horizontal element; and tensioning the
locking system to pull the lower horizontal element, the vertical
element, and the upper horizontal element together.
[0006] Various embodiments may provide a modular building kit,
comprising: at least one lower horizontal element; at least one
vertical element configured to form a hollow central portion; at
least one upper horizontal element; and at least one locking system
configured to connect the lower horizontal element, the vertical
element, and the upper horizontal element together.
[0007] Various embodiments may provide a modular building,
comprising: means for affixing at least one lower horizontal
element to a foundation; means for sliding a vertical element
configured to form a hollow central portion over a first raised
portion of the lower horizontal element; means for sliding a
vertical panel over a second raised portion of the lower horizontal
element and over a raised surface element of the vertical element;
means for sliding an upper horizontal element into the vertical
element and the vertical panel; means for affixing a locking system
between the lower horizontal element and the upper horizontal
element; and means for tensioning the locking system to pull the
lower horizontal element, the vertical element, and the upper
horizontal element together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings, which are incorporated herein and
constitute part of this specification, illustrate example aspects
of the claims, and together with the general description given
above and the detailed description given below, serve to explain
the features of the claims.
[0009] FIG. 1A illustrates a floor plan of a modular building
according to various embodiments.
[0010] FIGS. 1B and 1C illustrate interior views of rooms of the
embodiment module building of FIG. 1A.
[0011] FIGS. 1D and 1E illustrate exterior views of the embodiment
modular building of FIG. 1A.
[0012] FIG. 2A is an exterior view of a multi-floor modular
building according to various embodiments.
[0013] FIG. 2B is a close-up view of a portion of the embodiment
multi-floor modular building of FIG. 2A.
[0014] FIG. 3 is a cut-away view of a straight wall connection
between two wall panels and a vertical element according to various
embodiments.
[0015] FIG. 4A is a cut-away view of a corner wall connection
between two wall panels and a vertical element according to various
embodiments.
[0016] FIG. 4B is a cut-away view of a corner wall connection
between two window panels and a vertical element according to
various embodiments.
[0017] FIG. 5A is a cut-away view of a t-wall connection between
three wall panels and a vertical element according to various
embodiments.
[0018] FIG. 5B is a cut-away view of a t-wall connection between
two wall panels, a window panel, and a vertical element according
to various embodiments.
[0019] FIG. 6A is a cut-away view of a roof portion, vertical
element, and wall panel of a modular building according to various
embodiments.
[0020] FIG. 6B is another cut-away view of the embodiment modular
building of FIG. 6A.
[0021] FIG. 6C is a cut-away view of a roof portion and wall panel
of a modular building according to various embodiments.
[0022] FIG. 7A is a cut-away view of a lower horizontal element,
vertical element, and wall panel of a modular building according to
various embodiments.
[0023] FIG. 7B is a component diagram of a lower horizontal
element, vertical element, and wall panel being slid together to
form a modular building according to various embodiments.
[0024] FIG. 7C is a cut-away view of a lower horizontal element and
vertical element of a modular building according to various
embodiments.
[0025] FIG. 8 is a view of a roof portion of a modular building
according to various embodiments.
[0026] FIGS. 9A and 9B are cut-away views of roof portions of a
modular building according to various embodiments.
[0027] FIG. 10A is a cut-away view of a door panel of a modular
building according to various embodiments.
[0028] FIG. 10B is a cut-away view of another door panel of a
modular building according to various embodiments.
[0029] FIG. 11 is a cut-away view of a door panel of a modular
building according to various embodiments.
[0030] FIG. 12 is a cut-away view of a window panel of a modular
building according to various embodiments.
[0031] FIG. 13 is another cut-away view of the embodiment window
panel of FIG. 12.
[0032] FIG. 14 is a cut-away view of a roof panel according to
various embodiments with the aluminum composite panel removed.
[0033] FIG. 15 is a cut-away view of a roof panel according to
various embodiments.
[0034] FIGS. 16A-16C illustrate views of another modular building
according to various embodiments.
[0035] FIG. 17 is a cut-away view of a floor support for a modular
building according to various embodiments.
[0036] FIG. 18 illustrates different horizontal element
configurations according to various embodiments.
[0037] FIG. 19 illustrates horizontal elements arranged into an
H-frame suitable for installation on a foundation according to
various embodiments.
[0038] FIG. 20 illustrates various panels according to various
embodiments.
[0039] FIG. 21 illustrates a cut-away view a corner portion of a
modular building according to various embodiments.
[0040] FIG. 22 illustrates cut-away side views of two panel seal
configurations according to various embodiments.
DETAILED DESCRIPTION
[0041] The various aspects will be described in detail with
reference to the accompanying drawings. Wherever possible, the same
reference numbers will be used throughout the drawings to refer to
the same or like parts. References made to particular examples and
implementations are for illustrative purposes, and are not intended
to limit the scope of the claims. As used herein terms such as
"vertical", "horizontal", "upper", "lower", "foundation", "roof",
"wall", "over", "under", etc., are used as typically used in the
construction industry to relate to an orientation of a building
constructed on level ground, such as the orientation of a building
as shown in FIG. 1D.
[0042] Affordable housing developers are facing more obstacles to
building new projects, even though the need for affordable housing
grows stronger every year. In the United States (U.S.), the Federal
Low-Income Housing Tax Credit (LIHTC) program is providing less
funding than it did in prior years, while the cost of construction
is getting more expensive. Specifically, land, labor and material
costs continue to rise. As a result, individual development deals
that make financial sense are getting harder to find.
[0043] In the U.S. market, poor families are having an increasingly
difficult time finding an affordable place to live, due to high
rents, static incomes and a shortage of housing aid. An estimated
11 million families in the U.S. now pay more than half their income
on rent, a number that has grown steadily as the supply of
affordable housing shrinks. Similarly, in England, property is
unaffordable for one hundred thousand households a year. Almost one
hundred thousand households in England are being priced out of the
property market each year because of a shortage of affordable homes
to rent or buy. Additionally, the government in Germany estimates
that there is a need for three hundred and fifty thousand new
dwellings per year. The U.S., England, and Germany are merely just
three examples, and many more countries worldwide face the same
shortage of low income housing.
[0044] Commonly, modular buildings are built as a single unit or
large component in a factory. These single units and larger
components currently used for modular construction are costly to
transport to a building site and require large heavy lifting
equipment (e.g., a crane, etc.) for installation. The installation
of these single units and larger components currently requires a
large number of fasteners and is labor intensive. Additionally,
current modular buildings are expensive to expand. The cost and
labor intensiveness of current modular buildings and their
construction techniques has previously prevented modular buildings
from being used to address housing shortage worldwide.
[0045] Systems, methods, and devices of the various embodiments may
enable manufactured modular construction. The various embodiment
manufactured modular construction systems, methods, and devices may
offer a solution to the housing shortage worldwide that is less
than half the cost of the cost of current modular buildings.
Additionally, the various embodiment manufactured modular
construction systems, methods, and devices may provide labor cost
savings in that the various embodiments may enable embodiment
modular buildings to be erected in shorter amounts of time than the
time required for current modular buildings. Various embodiment
manufactured modular construction systems, methods, and devices may
provide modular buildings exceeding existing buildings in strength
and durability. Various embodiment manufactured modular
construction systems, methods, and devices may provide modular
buildings having a lower building cost than buildings built using
current building technologies. Various embodiment manufactured
modular construction systems, methods, and devices may provide
modular buildings in which structural elements (e.g., walls, roofs,
etc.) are held together without a need for glue or caulk.
[0046] Various embodiments may include interlocking vertical and
horizontal elements. In various embodiments, the vertical and/or
horizontal elements may be extruded, pultruded, cast, or otherwise
fabricated elements. In various embodiments, the profiles of the
vertical and horizontal elements may interlock together forming
vertical and/or horizontal channels for electric, data, plumbing,
HVAC (heating, ventilation, and air conditioning), and any other
type connections and/or utilities suitable for use in a modular
building. In various embodiments, the vertical and/or horizontal
elements may be formed from fiber-reinforced plastic (FRP) (also
referred to as fiber-reinforced polymer). In various embodiments,
the FRP may be colored and/or textured. In various embodiments, the
FRP may be a thermal insulator. In various embodiments, panels
(e.g., vertical panels, such as door panels, window panels, wall
panels, etc. and/or roof panels) may slide into the vertical and/or
horizontal elements. In various embodiments, vertical panels (e.g.,
wall panels, etc.) and/or roof panels may be formed from aluminum
composite with a structural foam (e.g., polyethylene foam, etc.).
As one example, the aluminum composite may be a layered composite
of aluminum sheeting layers adhered to the front and back of a
sheet of polyethylene. For example, the vertical panels and/or roof
panels may be formed from a foam sandwiched between an aluminum
frame. The structural foam may act as an insulator (e.g., an R-38
rated insulator) and a sound absorber. In various embodiments, a
roof profile may include an integrated gutter. In various
embodiments, the vertical and/or horizontal elements may include
raised features that interact with grooves on the panels (e.g.,
grooves on the vertical panels, such as door panels, window panels,
wall panels, etc. and/or grooves on the roof panels) to align the
vertical and/or horizontal elements with the adjoining panels as
tongue and groove joints. In alternative embodiments, the vertical
and/or horizontal elements may include grooves that may interact
with raised features on the panels (e.g., grooves on the vertical
panels, such as door panels, window panels, wall panels, etc.
and/or grooves on the roof panels) to align the vertical and/or
horizontal elements with the adjoining panels as tongue and groove
joints.
[0047] Various embodiments may include a locking system pulling
upper horizontal elements of an embodiment modular building toward
lower horizontal elements of the embodiment modular building to
thereby lock vertical elements and vertical panels in place between
the upper horizontal elements and the lower horizontal elements.
Various embodiments may include a locking system pulling upper
horizontal elements of an embodiment modular building toward the
foundation and/or lower floors of the embodiment modular building
to thereby lock vertical elements and vertical panels in place
between the upper horizontal elements and the foundation and/or
lower floors. In various embodiments, the locking system may not
require fasteners to connect the vertical elements to the vertical
panels of an embodiment modular building. In various embodiments,
the locking system may enable an embodiment modular building to be
erected or disassembled at a speed faster than the speed at which
current modular buildings are assembled/disassembled. In various
embodiments, the locking system may include a shock absorber. In
various embodiments, the shock absorber may include a rubber block,
a hydraulic system, a spring, or any other type shock dampening
device. In various embodiments, the locking system may not require
glue or caulk to hold the structural elements (e.g., the vertical
elements, vertical panels, horizontal elements, roof panels, etc.)
of an embodiment modular building together.
[0048] Various embodiments may provide modular buildings with
multi-floor layouts in various increments. In some embodiments, the
increments may be 4.2 foot (ft) (or 1.3 meter (m)) increments. In
various embodiments, components of a modular building may be energy
efficient. Various embodiments may provide a modular building that
may be assembled in two hours or less, such as 1.5 to 2 hours,
etc., by unskilled workers without a crane at the building site
rather than at a factory. Various embodiments may provide a modular
building that may be assembled by two unskilled workers at a rate
of 0.5 to 2 minutes (min) per square foot (sqft), such as 1 min per
sqft. Various embodiments may provide a modular building that
resists fire, water, mold, corrosion, and chemical damage. Various
embodiments may provide a modular building that is expandable by
adding additional vertical and/or horizontal elements. Various
embodiments may provide a modular building that may survive the
force of a hurricane. In various embodiments, the heaviest
component of the modular building may weigh fifty-five kilograms
(kg) (or one hundred and twenty-one pounds (lbs)). Various
embodiments may provide a modular building as a kit of components
that weight fifty-five kg or less and are assembled at a building
site.
[0049] Various embodiments may provide a modular building that is a
modular housing unit. The modular housing unit may have a foot
print of at least 4.1 m.times.8.1 m (or 13.4 ft.times.26.5 ft),
such as 4.1 to 20 m.times.8.1 to 30 m, etc. The modular housing
unit may provide a living space of at least 30.2 square meters (sq
m) (or 325 sqft), such as 325-1000 sqft. The modular housing unit
may include a bathroom module having a shower, sink, toilet, and
vent. The modular housing unit may include a walk in closet module.
The modular housing unit may include a modular kitchen cabinets
quick wall connect system. The modular housing unit may include a
kitchen sink with faucet. The modular housing unit may include a
refrigerator and/or freezer. The modular housing unit may include a
stove, such as three or more burner stove. The modular housing unit
may include a hot water heater. The modular housing unit may
include a split air condition (AC) unit. The modular housing unit
may include furniture such as a dining table and chairs, a sofa, a
flat screen television mount, a desk and chair(s), etc. The modular
housing unit may include a security system.
[0050] In some embodiments, a modular building may include a single
modular housing unit. In some embodiments, a modular building may
include two or more modular housing units. In some embodiments, a
modular building unit may be a modular apartment building formed
from stacking one or more modular housing unit on another modular
housing unit. In such apartment configurations, floor panels may
replace the roof panels in all but the upper most modular housing
units to thereby provide a floor for each successive stacked
modular housing unit. As a specific example, a modular apartment
building may include ten modular housing units on a first floor,
with ten additional modular housing units on a second floor, and
ten additional modular housing units on third floor, thereby
creating a three level and thirty unit modular apartment
building.
[0051] In various embodiments, lower horizontal elements may
connect to a foundation, such as a slab foundation, basement
foundation, piling foundation, etc. The lower horizontal elements
may be connected to the foundation with any type fastener, such as
pneumatic driven nails, wedge anchors, screws, adhesives, etc. In
various embodiments, the lower horizontal elements may have raised
features that interconnect with lower portions (i.e., the portions
toward the floor of the modular building when installed) of the
vertical panels (such as door panels, window panels, wall panels,
etc.). As used herein, "raised features" or "raised elements" may
refer to features that extend or protrude out from a surface. As
such, the raised features of the lower horizontal elements extend
or protrude from a surface of the lower horizontal elements. In
various embodiments, an upper portion of the lower horizontal
elements (i.e., the portion of the lower horizontal elements that
is opposite the foundation side of the lower horizontal elements
when installed) may be formed as a tongue structure that inserts
into a groove structure of the vertical panels, such as door
panels, window panels, wall panels, etc., thereby joining the lower
horizontal elements with vertical panels by a tongue and groove
type joint. In alternative embodiments, the lower horizontal
elements may be formed as the groove structure and the tongue
structure may be formed on the vertical panels, such as door
panels, window panels, wall panels, etc., thereby joining the lower
horizontal elements with vertical panels by a tongue and groove
type joint.
[0052] In various embodiments, lower horizontal elements may
include a raised feature that interconnects with lower portions of
the vertical elements (i.e., the portion of the vertical elements
toward the floor of the modular building when installed). Vertical
elements may be hollow pillars having any suitable horizontal cross
sectional shape, such as polygonal (e.g., rectangular, etc.),
circular, oval, etc. In various embodiments, an upper portion of
the lower horizontal elements (i.e., the portion of the lower
horizontal elements that is opposite the foundation side of the
lower horizontal elements when installed) may be formed as raised
structure (e.g., a tenon structure) that inserts into a center
cavity portion (e.g., a mortise structure) of the vertical
elements, thereby joining the lower horizontal elements with
vertical elements in effect by a mortise and tenon type joint. In
various embodiments, the vertical elements may create the height of
each level of the modular building. In various embodiments,
vertical elements may have different profile shapes depending on
the type of joint needed to connect two vertical panels (e.g., door
panels, window panels, wall panels, etc.). As examples, some
vertical elements may have a profile shape to form a straight wall
between two vertical panels (e.g., door panels, window panels, wall
panels, etc.), some vertical elements may have a profile shape to
form a right angle corner between two vertical panels (e.g., door
panels, window panels, wall panels, etc.), some vertical elements
may have a profile shape to form a t-shaped corner between three
vertical panels (e.g., door panels, window panels, wall panels,
etc.), some vertical elements may have a profile shape to form a
cross shaped corner between four vertical panels (e.g., door
panels, window panels, wall panels, etc.). In various embodiments,
the vertical elements may have raised features on their sides that
interconnect with side portions (i.e., portions running generally
orthogonal to the floor and/or roof when installed) of the vertical
panels (such as door panels, window panels, wall panels, etc.). In
various embodiments, a side portion of the vertical elements (i.e.,
the portion of the vertical elements that is generally orthogonal
to the floor and/or roof when installed) may be formed as a tongue
structure that inserts into a groove structure of the vertical
panels, such as door panels, window panels, wall panels, etc.,
thereby joining the vertical elements with vertical panels by a
tongue and groove type joint. In alternative embodiments, a side
portion of the vertical elements (i.e., the portion of the vertical
elements that is generally orthogonal to the floor and/or roof when
installed) may be formed as a groove structure that a tongue
structure of the vertical panels, such as door panels, window
panels, wall panels, etc., inserts into, thereby joining the
vertical elements with vertical panels by a tongue and groove type
joint. In various embodiments, at least a portion of a locking
system, such as a lock rod, lock cable, shock absorber, and/or any
other portion of a locking system, may run through a hollow center
portion (or hollow central portion) of the vertical elements. The
hollow center portion of a vertical element may run the full
vertical length of the vertical element. In various embodiments, no
fasteners, glue, or caulk, may be needed to keep the vertical
elements in place during assembly of a modular building as the
vertical elements may be supported by the raised structure (e.g., a
tenon structure) of the horizontal elements that inserts into a
center cavity portion (e.g., a mortise structure) of the vertical
elements.
[0053] In various embodiments, the lower horizontal elements may be
configured so as to form slots between the raised features that
interconnect with lower portions of the vertical elements (i.e.,
the portion of the vertical elements toward the floor of the
modular building when installed) and the raised features that
interconnect with lower portions (i.e., the portions toward the
floor of the modular building when installed) of the vertical
panels (such as door panels, window panels, wall panels, etc.). The
slots formed in the lower horizontal elements may provide a gap
between the raised features that aligns with the raised features on
the sides of the vertical elements. The slots may enable the
vertical elements to slide fully into the horizontal elements.
[0054] In various embodiments, a roof truss may be a horizontal
element configured similar to the vertical elements. The roof truss
may include a hollow center portion that may run the full length of
the roof truss. The roof trusses may include raised features on
their sides that interconnect with side portions (i.e., portions
running generally parallel to the roof when installed) of the roof
panels. In various embodiments, a side portion of the roof truss
(i.e., the portion of the roof truss that is generally parallel to
the roof when installed) may be formed as a tongue structure that
inserts into a groove structure of the roof panels, thereby joining
roof truss with roof panels by a tongue and groove type joint.
[0055] In various embodiments, the vertical panels (such as door
panels, window panels, wall panels, etc.) and/or roof panels may be
formed from a sandwich of insulating foam (e.g., polyurethane foam,
etc.) between aluminum composite sheets. The aluminum composite
sheets may be a layered composite sheet of aluminum sheeting layers
adhered to the front and back of a sheet of polyethylene. A panel
seal may be inserted into the grooves of the vertical panels (such
as door panels, window panels, wall panels, etc.) and/or roof
panels that join to the vertical elements and/or horizontal
elements (e.g., lower horizontal elements, upper horizontal
elements, roof trusses, etc.) The panel seal may be formed from a
compressible material, such a plastic, rubber, or other type
material seal, that may act as a weather seal for the joints of the
modular building. The panel seal may form a flexible seal between
the vertical panels (such as door panels, window panels, wall
panels, etc.) and/or roof panels that join to the vertical elements
and/or horizontal elements (e.g., lower horizontal elements, upper
horizontal elements, roof trusses, etc.). The panel seal may be
affixed to the vertical panels (such as door panels, window panels,
wall panels, etc.) and/or roof panels, such as by glue, nails,
friction, physical arrangement of the surface of the vertical
panels (such as door panels, window panels, wall panels, etc.)
and/or roof panels, and/or any element in any other manner. The
presence of the panel seal at the joint connection points may
eliminate the need for caulking and/or glue in the modular
building. The panel seals may be flexible seals having one or more
raised flexible features (e.g., lips, wipers, bubbles, etc.)
extending from a main body of the panel seal. The raised flexible
features (e.g., lips, wipers, bubbles, etc.) may be compressed
toward the main body of the panel seal when the vertical panels
(such as door panels, window panels, wall panels, etc.), roof
panels, vertical elements and/or horizontal elements (e.g., lower
horizontal elements, upper horizontal elements, roof trusses, etc.)
are joined together and the compression of the raised flexible
features (e.g., lips, wipers, bubbles, etc.) may form compression
interlocks between the vertical panels (such as door panels, window
panels, wall panels, etc.) and/or roof panels that join to the
vertical elements and/or horizontal elements (e.g., lower
horizontal elements, upper horizontal elements, roof trusses,
etc.). In various embodiments, the raised flexible features (e.g.,
lips, wipers, bubbles, etc.) may be compressed to lie flat against
the main body of the panel seal when the structural elements of the
modular building (e.g., the vertical panels (such as door panels,
window panels, wall panels, etc.), roof panels, vertical elements
and/or horizontal elements (e.g., lower horizontal elements, upper
horizontal elements, roof trusses, etc.)) are joined together.
Additionally, the raised flexible features (e.g., lips, wipers,
bubbles, etc.) may mold to the mating surface of the structural
elements of the modular building (e.g., the vertical panels (such
as door panels, window panels, wall panels, etc.), roof panels,
vertical elements and/or horizontal elements (e.g., lower
horizontal elements, upper horizontal elements, roof trusses,
etc.)) when the structural elements are joined together. The
flexibility of the panel seals may compensate for tolerance
variations in the profiles of the vertical panels (such as door
panels, window panels, wall panels, etc.), roof panels, vertical
elements and/or horizontal elements (e.g., lower horizontal
elements, upper horizontal elements, roof trusses, etc.),
especially when such structural elements of the modular building
are formed from FRP. As the vertical panels (such as door panels,
window panels, wall panels, etc.), roof panels, vertical elements
and/or horizontal elements (e.g., lower horizontal elements, upper
horizontal elements, roof trusses, etc.) are joined together, the
panel seals may compress (e.g., the raised flexible features (e.g.,
lips, wipers, bubbles, etc.) may compress toward the main body of
the panel seal, and/or the main body of the panel seal may
compress) and the compression may provide the required tolerances
for the structural elements of the modular building to fit
together, as well as may act as a shock absorber between the
structural elements. This compression of the panel seals may make
the structural elements of the modular building (e.g., the vertical
panels (such as door panels, window panels, wall panels, etc.),
roof panels, vertical elements and/or horizontal elements (e.g.,
lower horizontal elements, upper horizontal elements, roof trusses,
etc.)) easier to fit together. Additionally, by compensating for
tolerance variation in the structural elements of the modular
building (e.g., the vertical panels (such as door panels, window
panels, wall panels, etc.), roof panels, vertical elements and/or
horizontal elements (e.g., lower horizontal elements, upper
horizontal elements, roof trusses, etc.)), this compression of the
panel seals may prevent modular panels from not fitting together at
a build site and needing to be shipped back to a supplier due to
not fitting, thereby overcoming the non-fitting problem faced in
assembling current modular buildings.
[0056] In various embodiments, the grooves of the vertical panels
(such as door panels, window panels, wall panels, etc.) and/or roof
panels interacting with the raised portions of the vertical
elements and/or horizontal elements (e.g., lower horizontal
elements, upper horizontal elements, roof trusses, etc.) may form
vertical and/or horizontal channels for electric, data, plumbing,
HVAC (heating, ventilation, and air conditioning), and any other
type connections and/or utilities suitable for use in a modular
building. Connections to outside utilities may be made by push
connections and/or other type connections to the connections and/or
utilities running through the modular building. The presence of the
vertical and/or horizontal channels may eliminate the need to make
holes in the walls of the modular building for connections and/or
utilities.
[0057] In various embodiments, upper horizontal elements may be the
mirror image of the lower horizontal elements. Said another way,
the upper horizontal elements may be inverted lower horizontal
elements. For example, the upper horizontal elements may have
raised features that interconnect with upper portions (i.e., the
portions toward the roof of the modular building when installed) of
the vertical panels (such as door panels, window panels, wall
panels, etc.). In various embodiments, an lower portion of the
upper horizontal elements (i.e., the portion of the upper
horizontal elements that is toward the foundation side of the upper
horizontal elements when installed) may be formed as a tongue
structure that inserts into a groove structure of the vertical
panels, such as door panels, window panels, wall panels, etc., or
vice-versa, thereby joining the upper horizontal elements with
vertical panels by a tongue and groove type joint. As another
example, the upper horizontal elements may include a raised feature
that interconnects with upper portions of the vertical elements
(i.e., the portion of the vertical elements toward the roof of the
modular building when installed). In various embodiments, a lower
portion of the upper horizontal elements (i.e., the portion of the
upper horizontal elements that is opposite the roof side of the
upper horizontal elements when installed) may be formed as raised
structure (e.g., a tenon structure) that inserts into a center
cavity portion (e.g., a mortise structure) of the vertical
elements, thereby joining the upper horizontal elements with
vertical elements in effect by a mortise and tenon type joint. As a
further example, the upper horizontal elements may be configured so
as to form slots between the raised features that interconnect with
upper portions of the vertical elements (i.e., the portion of the
vertical elements toward the roof of the modular building when
installed) and the raised features that interconnect with upper
portions (i.e., the portions toward the roof of the modular
building when installed) of the vertical panels (such as door
panels, window panels, wall panels, etc.). The slots formed in the
upper horizontal elements may provide a gap between the raised
features that aligns with the raised features on the sides of the
vertical elements. The slots may enable the upper horizontal
elements to slide fully into the vertical elements and the vertical
panels (such as door panels, window panels, wall panels, etc.). The
upper horizontal elements may trap the vertical elements and the
vertical panels (such as door panels, window panels, wall panels,
etc.) between the upper horizontal elements and the lower
horizontal elements.
[0058] In various embodiments, a locking system may hold the
vertical elements and the vertical panels (such as door panels,
window panels, wall panels, etc.) in place between the upper
horizontal elements and the lower horizontal elements. In various
embodiments, the locking system may include a multitude of rods or
cables that pull the upper horizontal elements toward the lower
horizontal elements, thereby locking all in-between components
(i.e., the vertical elements and the vertical panels (such as door
panels, window panels, wall panels, etc.) in place. In this manner,
the locking system may eliminate all common fasteners used in the
building industry and reduces the time to erect a modular building.
Similarly, the locking system may eliminate the need for glue or
caulk to be used to hold structural components (e.g., the vertical
elements and the vertical panels (such as door panels, window
panels, wall panels, etc.), horizontal elements, roof panels, etc.)
together. Additionally, the locking system may enable quick
disassembly of a building. In various embodiments, a shock
absorbing system may be incorporated into the locking system to
increase stress resistance during heavy wind loads, explosions,
and/or earthquakes. In various embodiments, the shock absorbing
system of the locking system may enable the roof to move and snap
back during a negative pressure spike. As such, various embodiments
may be flexible increasing the modular building's strength under
excessive external forces and an embodiment modular building may
pass the 8 pounds-per-square-inch (PSI) blast building
standard.
[0059] In various embodiments, a roof support may be configured to
affix to the upper horizontal elements. The roof support may extend
horizontally beyond the upper horizontal elements to support the
roof. In various embodiments, roof clamps may affix the roof panels
and roof trusses to the roof support and thereby to the external
vertical walls of the modular building formed by the joined the
vertical elements and the vertical panels (such as door panels,
window panels, wall panels, etc.). In various embodiments, a
weather seal for the roof section may be formed as a gutter forming
a channel to collect rain water.
[0060] In various embodiments, a floor support may be configured to
affix to the upper horizontal elements. In this manner, the floor
support may enable the construction of multi-floor modular
buildings. The floor support may be a horizontal element configured
to support a floor section and/or lower horizontal elements. In
various embodiments, a floor section may be similar in construction
to a roof as described herein and the floor section may be
supported by a protrusion from the floor support. The floor support
may extend horizontally beyond the upper horizontal elements to
support the floor. The lower horizontal elements of the next floor
of the modular building may be affixed to the floor support. The
floor support may separate each floor of the modular building and a
roof may be affixed to the top floor using a roof support as
described herein rather than another floor support.
[0061] FIGS. 1A-1E illustrate aspects of a modular building 100
according to various embodiments. As one example, the modular
building 100 may be a modular housing unit. The modular building
100 may be any size. As one example, the modular building 100 may
have a foot print of 4.1 m.times.8.1 m (or 13.4 ft.times.26.5 ft).
As an example, the modular building 100 may provide a living space
of 30.2 square meters (sq m) (or 325 sqft). With reference to FIGS.
1A-1E, FIG. 1A illustrates a floor plan of the modular building
100. As illustrated in FIG. 1A, the modular building 100 may
include various modules therein, such as a bathroom module, bedroom
module 115, and living room module 116. The bathroom module may
include a toilet and sink area 103 and shower area 104. The bedroom
module 115 may include a bed 101 and desk 102. The living room
module 116 may include cabinets 107, a refrigerator 105, table 106,
and sofa 108. The modular building may include a HVAC unit 109,
such as a split AC. Exterior walls 110 may form the outer portions
of the modular building 100 and interior wall 111 may separate the
interior rooms of the modular building 100.
[0062] FIGS. 1B and 1C illustrate interior views from the living
room module 116 and bedroom module 115, respectively, of the
embodiment module building 100. FIGS. 1D and 1E illustrate exterior
views of the modular building 100. As illustrated in FIGS. 1B-1E,
the walls of the modular building 100 may be formed from a series
of panels, such as wall panels 123, window panels 120, and door
panels 121, interconnected by vertical elements 131. The
interconnected panels and vertical elements 131 may support a roof
125 of the modular building 100.
[0063] FIG. 2A is an exterior view of a multi-floor modular
building 200 according to various embodiments. FIG. 2B is a
close-up view of a portion of the multi-floor modular building 200.
With reference to FIGS. 1A-2B, in various embodiments, modular
building units, such as modular building units similar to modular
building 100, may be stacked to form the multi-floor modular
building 200, such as a modular apartment building. For example,
three floors 201, 202, and 203 of modular building units may be
stacked on top of one another to form the multi-floor modular
building 200. In such multi-floor configurations, floor panels may
replace the roof panels in all but the upper most floor 203 of the
modular housing units to thereby provide a floor for each
successive stacked modular housing unit. As a specific example, the
multi-floor modular building 200 may include ten modular housing
units on a first floor 201, with ten additional modular housing
units on a second floor 202, and ten additional modular housing
units on third floor 203, thereby creating a three level and thirty
unit multi-floor modular building 200.
[0064] FIG. 3 is a cut-away view of a straight wall connection
between two wall panels 306 which correspond to wall panels 123 in
FIGS. 1A-1E and a vertical element 312 which corresponds to the
vertical element 131 in FIGS. 1A-1E according to various
embodiments. With reference to FIGS. 1A-3, in various embodiments,
the vertical element 312 may be formed from FRP. In various
embodiments, the FRP may be colored and/or textured. In various
embodiments, the FRP may be a thermal insulator. In various
embodiments, the vertical element 312 may be an extruded and/or
pultruded element formed so as to have a hollow central portion
329. However other suitable structural materials may be used. In
various embodiments, the vertical element 312 may create the height
for each level of a modular building. In various embodiments,
vertical elements may have different profile shapes depending on
the type of joint needed to connect two vertical panels (e.g., door
panels, window panels, wall panels, etc.). As illustrated in FIG.
3, the vertical element 312 may be a straight wall element
configured to form a straight wall connection between two panels,
such as two wall panels 306 (and/or window and/or door panels). In
various embodiments, the vertical element 312 may slide on to a
raised portion of the lower horizontal element 350 that may be
affixed to a foundation or floor.
[0065] In various embodiments, the wall panels 306 may be formed
from a foam 307 core sandwiched between an aluminum frame of
aluminum composite panels (ACPs) 308 and an aluminum profile frame
310. In various embodiments, the wall panels 306 may be structural
insulated panels (SIPs) formed from a sandwich of ACP or other hard
materials and foam. The ACP panels 308 may be a layered composite
of aluminum sheeting layers adhered to the front and back of a
sheet of polyethylene. The structural foam 307 (e.g., polyurethane
foam, etc.) may act as an insulator (e.g., an R-38 rated insulator)
and a sound absorber. However other suitable structural materials
may be used. The aluminum profile frame 310 may encircle the panel
306 and support panel seals 305. The panel seal 305 may be a
plastic, rubber, or other type material seal that may act as a
weather seal for the joints of the modular building. In this
manner, glue and/or caulk may not be needed for the joints of the
modular building. The ACP panels may extend beyond the foam 307
core and form a groove structure along the edge of the wall panels
306 that supports the aluminum profile frame 310 and panel seals
305 therein. In some embodiments, the aluminum profile frame 310
may clamp the panel seals 305 in place, and the aluminum profile
frame 310 and panel seals 305 may also form a groove structure
within the groove structure along the edge of the wall panels 306.
The groove structure formed by the aluminum profile frame 310 and
panel seals 305 along the edge of the wall panels 306 may slide
over a raised portion of the lower horizontal element 350 that may
be affixed to a foundation or floor.
[0066] In various embodiments, the vertical element 312 may have
raised features 315 on sides that interconnect with the panels,
such as the two wall panels 306 (e.g., door panels, window panels,
wall panels, etc.). The raised features 315 may form a tongue
structure that inserts into the groove structure formed by the
aluminum profile frame 310 and panel seals 305 along the edge of
the wall panels 306, thereby joining the vertical element 312 with
wall panels 306 by respective tongue and groove type joints. The
aluminum profile frame 310 may be curved metal that holds the panel
seal 305 in place. In various embodiments, the front of the panel
seal 305 may have flexible wipers that contact the raised features
315 to seal the aluminum profile frame 310 to the raised features
315. When the vertical element 312 and the wall panel 306 are
joined together, a channel 316, such as a vertical channel, may be
formed between the vertical element 312 and the wall panel 306. The
channel 316 may provide a passageway for electric, data, plumbing,
HVAC (heating, ventilation, and air conditioning), and any other
type connections and/or utilities suitable for use in a modular
building.
[0067] In various embodiments, the vertical element 312 may be
inserted over a shock absorber 304 affixed to the lower horizontal
element 350. The shock absorber 304 may fit within the hollow
central portion 329. A shock absorber 304 may be optional, and not
all vertical elements may include a shock absorber 304. A lock rod
302 may run through the hollow central portion 329 of the vertical
element 312. The lock rod 302 and/or shock absorber 304, may be
components of a locking system pulling upper horizontal elements
toward the lower horizontal elements and securing the vertical
element 312 and wall panels 306 in place. The lock rod 302 (or lock
cable, or other locking mechanism) may be tensioned during
installation to create force holding the modular building walls
together.
[0068] FIG. 4A is a cut-away view of a corner wall connection
between two wall panels 306 and a vertical element 412 according to
various embodiments. With reference to FIGS. 1A-4A, the corner wall
connection illustrated in FIG. 4A is similar to the straight wall
connection of FIG. 3, except that the vertical elements 412 and 312
differ. Vertical element 412 may be similar to vertical element
312, except that vertical element 412 may have a different shape to
form a right angle corner between two panels, such as wall panels
306. Specifically, the raised features 315 on sides that
interconnect with the panels, such as the two wall panels 306,
rather than being on opposite sides, may be on ninety-degree offset
sides of the vertical element 312.
[0069] FIG. 4B is a cut-away view of a corner wall connection
between two window panels 406 (which correspond to window panel 120
in FIGS. 1A-1E) and a vertical element 412. With reference to FIGS.
1A-4B, FIG. 4B illustrates an upper portion of the vertical element
412. The corner wall connection of FIG. 4B is similar to the corner
wall connection of FIG. 4A, except rather than two wall panels 306,
two window panels 406 are connected by the vertical element 412.
Additionally, the panel seal 405 in FIG. 4B is configured in an
alternative shape from the panel seal 305 of FIGS. 3 and 4A.
[0070] The window panels 406 may include a window pane 450 affixed
to a window frame profile 453 by a spacer 452 and lock bar 451. In
some embodiments, the window frame profile 453 may be formed from
aluminum. In some embodiments, the spacer 452 may be formed from
rubber. The window panels 406 may include panels 454 sandwiching
the window frame profile 453 therebetween. Similarly to the wall
panels 306, the window panels 406 may include an aluminum profile
frame 310 encircling the window panel 406 and supporting the panel
seals 405. The panel seal 405 may be a plastic, rubber, or other
type material seal that may act as a weather seal for the joints of
the modular building. The panels 454 may extend beyond the window
frame profile 453 and form a groove structure along the edge of the
window panels 406 that supports the aluminum profile frame 310 and
panel seals 405 therein. In some embodiments, the aluminum profile
frame 310 may clamp the panel seals 405 in place between raised
elements 315 and aluminum profile frame 310, and the aluminum
profile frame 310 and panel seals 405 may also form a groove
structure within the groove structure along the edge of the window
panels 406. The groove structure formed by the aluminum profile
frame 310 and panel seals 405 along the edge of the window panels
406 may slide over a raised portion of the lower horizontal element
350 that may be affixed to a foundation or floor. The raised
features 315 of the vertical element 412 may interconnect with the
panels 306, 406. The raised features 315 may form a tongue
structure that inserts into the groove structure formed by the
aluminum profile frame 310 and panel seals 405 along the edge of
the panels 306, 406, thereby joining the vertical element 412 with
panels 306, 406 by respective tongue and groove type joints. When
the vertical element 412 and the panels 306, 406 are joined
together, channels 316, such vertical channels, may be formed
between the vertical element 412 and the panels 306, 406 as
discussed above.
[0071] FIG. 5A is a cut-away view of a t-wall connection between
three wall panels and a vertical element according to various
embodiments. With reference to FIGS. 1A-5A, the t-wall connection
illustrated in FIG. 5A is similar to the straight wall connection
of FIG. 3 and the corner wall connections of FIGS. 4A and 4B,
except that the vertical elements 512, 312, and 412 differ.
Vertical element 512 may be similar to vertical elements 312, 412,
except that vertical element 512 may have a different shape to form
a three joint (i.e., t-shaped) corner between three panels, such as
wall panels 306. Specifically, the raised features 315 on sides
that interconnect with the panels, such as the three wall panels
306, offset ninety degrees from one another.
[0072] FIG. 5B is a cut-away view of a t-wall connection between
two wall panels 306, a window panel 406, and a vertical element
512. With reference to FIGS. 1A-5B, the t-wall connection
illustrated in FIG. 5A is similar to the t-wall connection in FIG.
5A, except the connection is made with panel seals 405 rather than
panel seals 305.
[0073] FIGS. 6A and 6B are cut-away views of a roof portion,
vertical element 612, and wall panel of an embodiments modular
building. With reference to FIGS. 1A-6B, the vertical element 612
may be any type vertical element, such as a straight wall vertical
element 312, corner vertical element 412, t-wall vertical element
512, etc. As illustrated in FIG. 6A, an upper horizontal element
610 may be inserted in the upper portion of the vertical element
612. The lock rod 302 may pass through the hollow central portion
329 of the vertical element 612 and be affixed to the upper
horizontal element 610, such as by a nut 620. The lock rod 302 may
be tensioned to pull the upper horizontal element 610 down onto the
vertical element 612 and the vertical element 612 down onto a
horizontal element 350 under the vertical element 612. The upper
horizontal element 610 may include panel seals 305 on a portion of
the upper horizontal element 610 that insert into the hollow
central portion 329 of the vertical element 612. Similarly, the
upper horizontal element 610 may insert into the groove portion of
the wall panel 306 formed by the aluminum profile frame 310 and
panel seals 305 along the edge of the wall panels 306. As
illustrated in FIG. 6B, the when the wall panel 306 is joined with
the upper horizontal element 610, a channel 316 may be formed
therebetween.
[0074] A roof support 616 may be configured to affix to the upper
horizontal element 610. The roof support 616 may be a set of
elongated bars or hollow frame. The roof support 616 may extend
horizontally beyond the upper horizontal elements 610 to support a
roof panel 630. In various embodiments, roof clamps 604 may affix
the roof panels 630 and roof trusses 902 (see FIGS. 9A and 9B) to
the roof support 616 and thereby to the external vertical walls of
the modular building formed by the joined vertical elements 612 and
the wall panels 306. In various embodiments, the roof panels 630
may be formed from a foam 632 core sandwiched between an aluminum
frame of aluminum composite panels (ACPs) 631 and an aluminum
profile frame 310. In various embodiments, the roof panels 630 may
be structural insulated panels (SIPs) formed from a sandwich of ACP
or other hard materials and foam. The ACPs 631 may be a layered
composite of aluminum sheeting layers adhered to the front and back
of a sheet of polyethylene. The structural foam 632 (e.g.,
polyurethane, etc.) may act as an insulator (e.g., an R-38 rated
insulator) and a sound absorber. The aluminum profile frame 310 may
encircle the panel 630 and support panel seals 305. The panel seal
305 may be a plastic, rubber, or other type material seal that may
act as a weather seal for the joints of the modular building. The
ACP panels 630 may extend beyond the foam 632 core and form a
groove structure along the edge of the roof panel 630 that supports
the aluminum profile frame 310 and panel seals 305 therein. In some
embodiments, the aluminum profile frame 310 may clamp the panel
seals 305 in place, and the aluminum profile frame 310 and panel
seals 305 may also form a groove structure within the groove
structure along the edge of the roof panel 630. The groove
structure formed by the aluminum profile frame 310 and panel seals
305 along the edge of the roof panel 630 may be affixed to the roof
support 616 by one or more roof clamps 604. In various embodiments,
a weather seal for the roof section may be formed as a gutter 615
forming a channel to collect rain water. The gutter 615 may insert
into a groove of the roof panel 630.
[0075] In some embodiments, a panel bracket 602 may affix a portion
of a wall panel 306 to the vertical element 612. In some
embodiments, a roof support fastener 605, such as a bolt, etc., may
extend through the roof clamps 604, roof support, and upper
horizontal elements 610 to clamp the roof panel 630 and upper
horizontal element 610 to the panels of the modular building, such
as the wall panels 306.
[0076] FIG. 6C is a cut-away view of a roof portion and wall panel
306 of a modular building according to various embodiments. With
reference to FIGS. 1A-6C, the roof portion of FIG. 6C is similar to
the roof portion of FIGS. 6A and 6B, except a different gutter 660
shape and different panel seal 405 shape is shown.
[0077] FIG. 7A is a cut-away view of a lower horizontal element
350, vertical element 612, and wall panel 306 connected together.
With reference to FIGS. 1A-7A, the vertical element 612 may be any
type vertical element, such as a straight wall vertical element
312, corner vertical element 412, t-wall vertical element 512, etc.
FIG. 7A illustrates one type of shock absorber 304 suitable for use
with the various embodiments. In the shock absorber 304 may be
formed from a rubber block 701 supported between a top plate 702
and bottom plate 703. In other embodiments, the rubber block 701
may be replace with a hydraulic system (e.g., a hydraulic cylinder,
etc.), spring, or other type shock absorber. The top plate 702 may
be compressed against the rubber block 701 by a fastener 706, such
as a bolt, etc., that passes through the top plate 702, rubber
block 701, and bottom plate 703. The fastener 706 may affix the
shock absorber 304 to a lower horizontal element 350. The bottom
plate 703 may be compressed against the rubber block 701 by one or
more fasteners 705 (e.g., one or more bolts, etc.), such as two
fasteners 705, etc., that passes through the bottom plate 703,
rubber block 701, and top bottom plate 702. The one or more
fasteners 705 may connect to a catch plate 704 that is affixed to
the lock rod 302. The catch plate 704 may be affixed to the lock
rod 302 in any manner. For example, the lock rod 302 may slide into
a slot in the catch plate 704. The rubber block 701 may expand and
contract between the upper plate 702 and lower plate 703 to dampen
forces acting on the vertical element 612. In various embodiments,
the shock absorber 304 may be incorporated into the locking system
to increase stress resistance during heavy wind loads, explosions,
and/or earthquakes. In various embodiments, the shock absorber 304
of the locking system may enable the roof to move and snap back
during a negative pressure spike. The tension of the lock rod 302
and shock absorber 304 may pull the upper horizontal elements 610
down toward the lower horizontal elements 350 to secure the walls
of the modular building. As seen in FIG. 7A, the lower horizontal
element 350 may include panel seals 305 on the rail feature 725 of
the lower horizontal element 350 contacting the inner surface of
the vertical element 612 when inserted into the hollow central
portion 329 of the vertical element 612.
[0078] FIG. 7B is a component diagram of a lower horizontal element
350, vertical element 512, and wall panel 306 being slid together.
With reference to FIGS. 1A-7B, the lower horizontal element 350 may
include a first raised portion 720 and a second raised portion 721.
The first raised portion 720 and the second raised portion 721 may
both include rail features 725. The first raised portion 720 may be
separated from the second raised portion 721 so as to form a slot
722 therebetween. The slot 722 may receive the raised elements 315
of the vertical element 512 when slid together. The vertical
element 512 is shown being slid over the shock absorber 304. The
first raised portion 720 of the lower horizontal element 350 may
include a panel seal 405 affixed to the rail elements 725, while
the second raised portion 721 may not include a panel seal on the
rail elements 725.
[0079] FIG. 7C is a cut-away view of a lower horizontal element 350
and vertical element 612 connected together with a window panel
406. With reference to FIGS. 1-7C, a floor 790 is also visible in
FIG. 7C.
[0080] FIG. 8 is a view of a roof portion of a modular building.
With reference to FIGS. 1A-8, the roof portion is similar to the
roof portions shown in FIGS. 6A-6C, except no gutter is shown. The
roof support is illustrated clamped to the wall of the building
formed by the vertical element 612 and the wall panel 306 by the
roof clamps 604. As illustrated in FIG. 8, the roof clamps 604 may
extend over the panel seal 405 of the roof panel 630 and into the
groove formed by the aluminum frame profile 310.
[0081] FIGS. 9A and 9B are cut-away views of roof portions of a
modular building according to various embodiments. With reference
to FIGS. 1A-9B, FIG. 9A shows a roof truss 902 connected between
two roof panels 630 with one shape of panel seal 305 while FIG. 9B
shows the roof truss 902 connected between two roof panels 630 with
another shape of panel seal 405. Roof trusses 902 may be similar to
vertical elements (e.g., vertical elements 412, 612, etc.) and may
connect two roof panels 630 together. The roof trusses 902 may
include a hollow center portion 904.
[0082] In various embodiments, the roof trusses 902 may have raised
features 903 on sides that interconnect with the panels, such as
the two roof panels 630. The raised features 903 may form a tongue
structure that inserts into the groove structure formed by the
aluminum profile frame 310 and panel seals 305, 405 along the edge
of the roof panels 630, thereby joining the roof trusses 902 with
roof panels 630 by respective tongue and groove type joints. When
the roof trusses 902 with roof panels 630 are joined together, a
channel 905, such as a horizontal channel, may be formed between
the roof trusses 902 with roof panels 630. The channel 905 may
provide a passageway for electric, data, plumbing, HVAC (heating,
ventilation, and air conditioning), and any other type connections
and/or utilities suitable for use in a modular building.
[0083] FIGS. 10A-11 are cut away views of embodiment door panels
1001. With reference to FIGS. 1A-11, the door panel 1001 that
corresponds to the door panel 121 in FIGS. 1B-1E and may include a
door 1002, door stop 1003, a door frame profile 1030, aluminum
composite panels (ACPs) 1008, a foam core 1007, and an aluminum
profile frame 310. The ACPs 1008 may be a layered composite of
aluminum sheeting layers adhered to the front and back of a sheet
of polyethylene. In various embodiments, the wall panels door panel
1001 may be structural insulated panels (SIPs) formed from a
sandwich of ACP or other hard materials and foam. The door may be
affixed to the door frame profile 1030 by one or more hinges. The
door panel 1001 may include panels 1008 sandwiching the door frame
profile 1030 and foam core 1007 therebetween. Similarly to the wall
panels 306 and the window panels 406, the door panels 1001 may
include an aluminum profile frame 310 encircling the door panel
1001 and supporting the panel seals 305 and/or 405. The panels 1008
may extend beyond the door frame profile 1030 and foam core 1007
and form a groove structure along the edge of the door panels 1001
that supports the aluminum profile frame 310 and panel seals 305,
405 therein. In some embodiments, the aluminum profile frame 310
may clamp the panel seals 305, 405 in place, and the aluminum
profile frame 310 and panel seals 305, 405 may also form a groove
structure within the groove structure along the edge of the door
panels 1001. The groove structure formed by the aluminum profile
frame 310 and panel seals 305, 405 along the edge of the door
panels 1001 may slide over a raised portion (e.g., a raised portion
include the rail features 725) of the lower horizontal element 350
that may be affixed to a foundation or floor. The aluminum profile
frame 310 may rest on the rail features 725 of the lower horizontal
element 350 and a channel 316 may be formed between the lower
horizontal element 350 and aluminum profile frame 310 between the
rail features 725. The raised features 315 of the vertical element
(e.g., vertical element 612, 512, etc.) may interconnect with the
door panel 1001. The raised features 315 may form a tongue
structure that inserts into the groove structure formed by the
aluminum profile frame 310 and panel seals 305, 405 along the edge
of the door panel 1001, thereby joining the vertical element with
the door panel 1001 by respective tongue and groove type joints.
When the vertical element and the panel 1001 are joined together,
channels 316, such as vertical channels, may be formed between the
vertical element and the panels 1001 as discussed above.
Additionally, when the horizontal element (e.g., upper horizontal
element 610 and/or lower horizontal element 350, etc.) are joined
together, channels 316, such as horizontal channels, may be formed
between the horizontal element and the panels 1001 as discussed
above.
[0084] FIGS. 12 and 13 illustrate cut-away views of the embodiment
window panel 406. With reference to FIGS. 1A-13, in alternative
configurations, the window panel may include additional foam core
1302 between the panels 454. The dimensions of spacer 452 may also
be modified to accommodate thicker or thinner window panels.
[0085] FIGS. 14 and 15 are cut-away views of a roof panel 630
according to various embodiments. With reference to FIGS. 1A-15,
FIG. 14 shows the roof panel 630 with the aluminum composite panel
631 removed, while FIG. 15 shows the roof panel 630 with the
aluminum composite panel 631 installed. In FIG. 14, the aluminum
profile frame 310 encircling the roof panel is visible supporting
the panel seal 305.
[0086] FIGS. 16A-16C illustrate views of another modular building
1600 according to various embodiments. With reference to FIGS.
1A-16C, the modular building 1600 may include more than two rooms
and may be larger than the building of FIGS. 1A-1E.
[0087] FIG. 17 is a cut-away view of a floor support 1703 for a
modular building according to various embodiments. With reference
to FIGS. 1A-17, the floor support 1703 may be configured to affix
to the upper horizontal elements 610. In this manner, the floor
support 1703 may enable the construction of multi-floor modular
buildings. The floor support 1703 may include a floor anchor 1707,
such as a bolt, etc., running through a hollow center portion of
the floor support 1703 and connecting to the upper horizontal
portion 610 of the lower level and the lower horizontal portion 350
of the upper level. The floor support 1703 may be a horizontal
element configured to support a floor section 1702 and/or lower
horizontal elements 350. In various embodiments, a floor section
1702 may be similar in construction to a roof as described herein,
such as formed from a series of panels and trusses. The floor
section 1702 may be supported by a protrusion 1704 extending inward
toward the center of the modular building from the floor support
1703. The floor portion 1702 may be include passages 1705 therein
to provide a passageway for electric, data, plumbing, HVAC
(heating, ventilation, and air conditioning), and any other type
connections and/or utilities suitable for use in a modular
building. The floor support 1703 may extend horizontally beyond the
upper horizontal elements 610 on which it is affixed to support the
floor 1702. The lower horizontal elements 350 of the next floor of
the modular building may be affixed to the floor support 1703. The
floor support 1703 may separate each floor of the modular building
and a roof may be affixed to the top floor using a roof support 616
as described herein rather than another floor support 1703. An
upper portion of the floor support 1703 may be narrower than the
lower horizontal elements 350 to create a lip 1706 to contact the
floor 1702.
[0088] FIG. 18 illustrates different horizontal element
configurations 1902, 1904, 1906, 1908, and 1910 according to
various embodiments. With reference to FIGS. 1A-18, a horizontal
element configuration 1902 may be a straight element with no slots
722. In another configuration 1904, the horizontal element may
include a slot 722 between a first raised portion and second raised
portion and holes 1901 passing through the horizontal element to
enable connections to other elements, such as a foundation, etc. In
another configuration 1906, the horizontal element may include a
panel seal 405 on the first raised portion. In another
configuration 1908, the horizontal element may include a shock
absorber 304. In another configuration 1910, the horizontal element
may include a bracket 1903 at one end. Horizontal elements
1902-1910 may include rail features 725 along their lengthwise
directions over which a vertical element and/or panel may be slid
and/or that may slide into a vertical element and/or panel. A slot
between the rail features 725 may create the channel 316 between
the panels and the horizontal elements 1902-1910 when joined
together.
[0089] FIG. 19 illustrates lower horizontal elements 350 arranged
into an H-frame 2000 suitable for installation on a foundation or
floor. With reference to FIGS. 1A-19, the lower horizontal elements
350 may include shock absorbers 304. Once the H-frame is affixed to
the foundation or floor, the vertical elements and panels discussed
herein may be slide onto the lower horizontal elements 350 to form
the walls of a modular building.
[0090] FIG. 20 illustrates such example panels according to various
embodiments. With reference to FIGS. 1A-20, FIG. 20 illustrates a
roof panel 630, a wall panel 306, a door panel 1001, and a window
panel 406. The panels slide over the rail features 725 on the lower
horizontal elements 350. Similarly, the rail features 725 of the
upper horizontal elements 350 slide into the panels. In various
embodiments, the roof panel 630, the wall panel 306, the door panel
1001, and/or the window panel 406 may be structural insulated
panels (SIPs) formed from a sandwich of ACP or other hard materials
and foam.
[0091] FIG. 21 illustrates a cut-away view a corner portion of a
modular building according to various embodiments. With reference
to FIGS. 1A-21, FIG. 21 illustrates an embodiment modular building
in which separate inside walls are affixed inside of the vertical
elements and/or vertical panels (e.g., wall panels, door panels,
window panels, etc.). The wall panels 2101 shown in FIG. 21 may be
similar to the wall panels 123 and 306 described herein. The
vertical element 2102 shown in FIG. 21 may be similar to the
vertical element 412 described herein. The lower horizontal element
2107 shown in FIG. 21 may be similar to horizontal element 350
described herein and may further be configured to support the
insertion of an inside wall (or inner wall) disposed toward the
inside of the modular building affixed to the wall panels 2101. The
locking system 2103 may be disposed between the inside wall and the
vertical element 2102 and/or wall panels 2101. The locking system
2103 may connect an upper horizontal element to the lower
horizontal element 2107. The locking system 2103 between the inside
wall and the vertical element 2102 and/or wall panels 2101 may be
tensioned to pull the upper horizontal element toward the lower
horizontal element to thereby lock vertical elements (e.g.,
vertical element 2102) and vertical panels (e.g., wall panels 2101)
in place between the upper horizontal elements and the lower
horizontal element 2107. The locking system 2103 may include an
upper lock bar 2106 (or lock rod, cable, etc.) coupled to a lower
lock bar 2105 (or lock rod, cable, etc.) by a shock absorber 2104.
For example, the shock absorber 2104 may be a metal (e.g., steel,
etc.) oval spring, rubber block, hydraulic system, etc. The shock
absorber 2104 may operate similar to shock absorber 304 as
described herein.
[0092] In alternative embodiments, the locking systems as described
herein may not interact with the lower horizontal elements 350.
Rather, the locking systems may pull the upper horizontal elements
610 toward the foundation and/or floor to thereby lock vertical
elements and vertical panels in place between the upper horizontal
elements and the foundation and/or floor. For example, lock rod 302
(or lock cable, or other locking mechanism) may connect to a bolt
in the foundation on a first level of a modular building and/or
lock rod 302 (or lock cable, or other locking mechanism) may
connect to a bolt in a floor of a second or higher level of a
modular building. The lock rod 302 (or lock cable, or other locking
mechanism) may be tensioned during installation to create force
holding the modular building walls together.
[0093] FIG. 22 illustrates cut-away side views of two different
panel seals 305 and 405. With reference to FIGS. 1A-22, the panel
seal 305, 405 may be formed from a compressible material, such a
plastic, rubber, or other type material seal, that may act as a
weather seal for the joints of the modular building. The panel seal
305, 405 may form a flexible seal between the vertical panels (such
as door panels, window panels, wall panels, etc.) and/or roof
panels that join to the vertical elements and/or horizontal
elements (e.g., lower horizontal elements, upper horizontal
elements, roof trusses, etc.). The panel seal 305, 405 may be
affixed to the vertical panels (such as door panels, window panels,
wall panels, etc.) and/or roof panels, such as by glue, nails,
friction, physical arrangement of the surface of the vertical
panels (such as door panels, window panels, wall panels, etc.)
and/or roof panels, and/or any in any other manner. The presence of
the panel seal 305, 405 at the joint connection points may
eliminate the need for caulking and/or glue in the modular
building. The panel seal 305, 405 may be a flexible seal having one
or more raised flexible features 2201 (e.g., lips, wipers, bubbles,
etc.) extending from a main body 2202 of the panel seal 305, 405.
The raised flexible features 2201 may be compressed toward the main
body 2202 (e.g., in the direction "C") when the vertical panels
(such as door panels, window panels, wall panels, etc.), roof
panels, vertical elements and/or horizontal elements (e.g., lower
horizontal elements, upper horizontal elements, roof trusses, etc.)
are joined together (e.g., by being inserted in the direction "I").
The compression of the raised flexible features 2201 may form
compression interlocks between the vertical panels (such as door
panels, window panels, wall panels, etc.) and/or roof panels that
join to the vertical elements and/or horizontal elements (e.g.,
lower horizontal elements, upper horizontal elements, roof trusses,
etc.). In various embodiments, the raised flexible features 2201
may be compressed to lie flat against the main body 2202 when the
structural elements of the modular building (e.g., the vertical
panels (such as door panels, window panels, wall panels, etc.),
roof panels, vertical elements and/or horizontal elements (e.g.,
lower horizontal elements, upper horizontal elements, roof trusses,
etc.)) are joined together. Additionally, the raised flexible
features 2201 may mold to the mating surface of the structural
elements of the modular building (e.g., the vertical panels (such
as door panels, window panels, wall panels, etc.), roof panels,
vertical elements and/or horizontal elements (e.g., lower
horizontal elements, upper horizontal elements, roof trusses,
etc.)) when the structural elements are joined together. The
flexibility of the panel seal 305, 405 may compensate for tolerance
variations in the profiles of the vertical panels (such as door
panels, window panels, wall panels, etc.), roof panels, vertical
elements and/or horizontal elements (e.g., lower horizontal
elements, upper horizontal elements, roof trusses, etc.),
especially when such structural elements of the modular building
are formed from FRP. As the vertical panels (such as door panels,
window panels, wall panels, etc.), roof panels, vertical elements
and/or horizontal elements (e.g., lower horizontal elements, upper
horizontal elements, roof trusses, etc.) are joined together, the
panel seal 305, 405 may compress (e.g., the raised flexible
features 2201 may compress toward the main body 2202 in the
direction "C", and/or the main body 2202 may compress in the
direction "C") and the compression may provide the required
tolerances for the structural elements of the modular building to
fit together, as well as may act as a shock absorber between the
structural elements. This compression of the panel seal 305, 405
may make the structural elements of the modular building (e.g., the
vertical panels (such as door panels, window panels, wall panels,
etc.), roof panels, vertical elements and/or horizontal elements
(e.g., lower horizontal elements, upper horizontal elements, roof
trusses, etc.)) easier to fit together. Additionally, by
compensating for tolerance variation in the structural elements of
the modular building (e.g., the vertical panels (such as door
panels, window panels, wall panels, etc.), roof panels, vertical
elements and/or horizontal elements (e.g., lower horizontal
elements, upper horizontal elements, roof trusses, etc.)), this
compression of the panel seal 305, 405 may prevent modular panels
from not fitting together at a build site and needing to be shipped
back to a supplier due to not fitting. While FIG. 22 illustrates
two example configurations of the panel seal 305, 405, other
configurations of panel seals, such as other configurations with
different shapes of raised features 2201 and main bodies 2202,
different numbers of raised features 2201, etc., may be substituted
for the panel seals 305 and 405 described herein.
[0094] Various aspects illustrated and described are provided
merely as examples to illustrate various features of the claims.
However, features shown and described with respect to any given
aspect are not necessarily limited to the associated aspect and may
be used or combined with other aspects that are shown and
described. Further, the claims are not intended to be limited by
any one example aspect.
[0095] The foregoing method descriptions and the process flow
diagrams are provided merely as illustrative examples and are not
intended to require or imply that the steps of the various aspects
must be performed in the order presented. As will be appreciated by
one of skill in the art the order of steps in the foregoing aspects
may be performed in any order. Words such as "thereafter," "then,"
"next," etc. are not intended to limit the order of the steps;
these words are simply used to guide the reader through the
description of the methods. Further, any reference to claim
elements in the singular, for example, using the articles "a," "an"
or "the" is not to be construed as limiting the element to the
singular.
[0096] The preceding description of the disclosed aspects is
provided to enable any person skilled in the art to make or use the
claims. Various modifications to these aspects will be readily
apparent to those skilled in the art, and the generic principles
defined herein may be applied to other aspects without departing
from the scope of the claims. Thus, the claims are not intended to
be limited to the aspects described herein but are to be accorded
the widest scope consistent with the following claims and the
principles and novel features disclosed herein.
* * * * *