BACKGROUND
The present disclosure is directed to modular building units for use in the construction of a building. The modular building unit provides a modular system configured for rapidly erecting a building at a construction site or work site. In particular, the modular building unit facilitates stacking multiple units on top of each other to erect the building.
SUMMARY
In one aspect, a method of constructing a building generally comprises providing a first modular building unit including a locking assembly integrated into the first modular building unit. Providing a second modular building unit including a locking assembly integrated into the second modular building unit. Placing the first and second modular building units in adjoining relation to each other at a building site. Engaging the locking assembly of the first modular building unit with the second modular building unit to position the second modular building unit relative to the first modular building unit. Engaging the locking assembly of the second modular building unit with the locking assembly of the first modular building unit to connect the second modular building unit to the first modular building unit.
In another aspect, a modular building unit assembly for use in constructing a building generally comprises a first modular building unit and a locking assembly mounted on the first modular building unit. The locking assembly is configured to position a second modular building unit located above the first modular building unit relative to the first modular building unit, and connect the first modular building unit to a locking assembly of the second modular building unit.
In yet another aspect, a locking assembly for use in building construction generally comprises a locking body configured to be mounted on a first modular building unit and extend in a first direction away from the first modular building unit. The locking body is configured to receive and engage another locking assembly of a second modular building unit for locating the first modular building unit and the second modular building unit with respect to each other. A locking extension is configured to be mounted on the first modular building unit and extend in a second direction, opposite the first direction, away from the first modular building unit. The locking extension is configured to engage another locking body on a third modular building unit to lock the first modular building unit to the third modular building unit.
In still another aspect, a locking body for use in a locking assembly of a modular building unit is configured for mounting on a modular building unit and extending in a first direction away from the modular building unit when the locking body is mounted on the modular building unit. The locking body comprises a top wall, a pair of opposing side walls, a pair of opposing end walls, and a bottom. At least one of the side walls and the end walls is tapered such that a lateral dimension of the locking body at the bottom is greater than a corresponding lateral dimension of the locking body at the top wall. The locking body is configured to receive and engage a locking assembly of another modular building unit for locating said other modular building unit with respect to the modular building unit.
In yet another aspect, a building generally comprises a plurality of modular building units. Each modular building unit includes an integrated locking assembly locking a first modular building unit to a second modular building unit below the first modular building unit. The integrated locking assembly is configured to position a third modular building unit located above the first modular building unit relative to the first modular building unit, and connect the first modular building unit to a locking assembly of the second modular building unit.
In still another aspect, a method of constructing a building generally comprises providing a first modular building unit. Providing a second modular building unit including a locking assembly integrated into the second modular building unit. Placing the first and second modular building units in adjoining relation to each other at a building site. The step of placing including engaging first structure of the first modular building unit with second structure of the second modular building unit so that the engagement of the first structure and the second structure guides movement of the first and second modular building units relative to each other.
In yet another aspect, a building component for use in constructing a building generally comprises a first building component including an integrated locking assembly mounted on the building component. The integrated locking assembly is configured to position a second building component located above the first building component relative to the first building component, and connect the first building component to a locking assembly of the second building component.
In still another aspect, a method of constructing a building generally comprises providing a first building unit including a locking assembly integrated into the first building unit. Providing a second building unit including a locking assembly integrated into the second building unit. Placing the first and second building units in adjoining relation to each other at a building site. Engaging the locking assembly of the second building unit with the locking assembly of the first building unit to connect the second building unit to the first building unit. The engagement between the locking assemblies being free of a threaded connection.
DESCRIPTION OF THE DRAWINGS
FIG. 1A is a perspective of a modular building unit;
FIG. 1B is a perspective of a wall assembly of the modular building unit;
FIG. 1C is a perspective of a ceiling assembly of the modular building unit;
FIG. 1D is a perspective of a floor assembly of the modular building unit;
FIG. 2 is an illustration of two modular building units being stacked on top of each other;
FIG. 3 is a perspective of two modular building units stacked on top of each other;
FIG. 4 is an enlarged fragmentary view of the modular building unit showing a lifting tackle attached to a key box on a frame of the modular building unit;
FIG. 5 is an enlarged fragmentary view taken as indicated in FIG. 1;
FIG. 6 is an enlarged fragmentary view taken as indicated in FIG. 1;
FIG. 7 is a perspective of the modular building unit in FIG. 1 showing an alternative guide sleeve;
FIG. 8 is an enlarged fragmentary view taken as indicated in FIG. 7;
FIG. 9 is an enlarged fragmentary view taken as indicated in FIG. 7;
FIG. 10 is an enlarged fragmentary view taken as indicated in FIG. 3;
FIG. 11 is an enlarged fragmentary view taken as indicated in FIG. 3;
FIG. 12 is the enlarged fragmentary view taken as indicated in FIG. 11 with cross members of the modular building units shown as transparent;
FIG. 13 is a schematic illustration of a modular building unit mounted on top of another modular building unit;
FIG. 14A is an enlarged fragmentary view of FIG. 3 with cross members and guide sleeves of the modular building units shown as transparent and the locking mechanism in an unlocked configuration;
FIG. 14B is an enlarged fragmentary view of FIG. 3 with cross members and guide sleeves of the modular building units shown as transparent and the locking mechanism in locked configuration;
FIG. 14C is a schematic perspective from a first vantage of the locking mechanism and key box in a locked configuration;
FIG. 14D is a schematic perspective from a second vantage of the locking mechanism and key box in the locked configuration;
FIG. 15A is a perspective of the key box from a front and left vantage;
FIG. 15B is a perspective of the key box from a rear and right end vantage;
FIG. 16 is a front view of the key box;
FIG. 17 is a top view of the key box;
FIG. 18 is a perspective of another embodiment of a key box;
FIG. 19 is a perspective of another embodiment of a key box;
FIG. 20 is an elevation of a locking bar of the modular building unit;
FIG. 21 is an enlarged fragmentary perspective of a top of the locking bar;
FIG. 22 is an enlarged fragmentary perspective of a bottom of the locking bar;
FIG. 23 is a fragmentary perspective of two building units of another embodiment stacked on top of each other;
FIG. 24 is an enlarged fragmentary perspective of FIG. 23 showing a beam of one of the building units as transparent;
FIG. 25 is a fragmentary perspective of a first building unit;
FIG. 26 is an illustration of the building units in FIG. 23 separated from each other and schematically showing a portion of locking assemblies on the building units;
FIG. 27 is a cross-section of the locking assemblies in FIG. 26;
FIG. 28 is a top view of the locking assemblies in FIG. 27;
FIG. 29 is a perspective of a key box of the first building unit in FIG. 25;
FIG. 30 is a top view of the key box in FIG. 26;
FIG. 31 is a bottom view of the key box in FIG. 26;
FIG. 32 is a front view of the key box in FIG. 26; and
FIG. 33 is a perspective of a locking fixture of the key box in FIG. 26.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DESCRIPTION
Referring to FIGS. 1A-1D, a modular building unit of the present disclosure is generally indicated at 11. The modular building unit 11 may be used in the construction of a building. For example, multiple assembled modular units 11 may be stacked on top of each other and disposed side-by-side to form a building. In the illustrated embodiment, the modular building unit 11 comprises a ceiling assembly 13, a pair of wall assemblies 15 attachable to opposite sides of the ceiling assembly, and a floor assembly 17 attachable to a bottom of the wall assemblies. The wall assemblies 15 may be movably (e.g., pivotably) attached to the ceiling assembly 13 or floor assembly 17 so that initially, a frame of the modular building unit 11 may be formed in a collapsed or flattened state and expanded into the fully erected modular frame shown in FIG. 1. In one embodiment, the frame is erected in an assembly plant and other components (not shown) are attached to the frame to create the modular building unit for installation at the construction site. In some circumstances, the modular building unit may have essentially everything needed for a finished room or rooms prior to being assembled with other modular building units. However, for simplicity only the frame is shown and described herein. Moreover, it will be understood that the frame can itself be considered a “modular building unit,” as can any unit with any increment of finishing from the bare frame to the fully finished room(s). The level of finish applied to the modular building unit can be different at the time the modular building units are connected together to form a building. Moreover, the person of ordinary skill in the art will appreciate that the configuration of the frame of the modular building unit 11 may be other than described (often as dictated by the requirements of a particular building project) within the scope of the present invention. In one non-limiting example, the modular building unit may comprise only a portion of the frame that would define a room or other building space. As will be explained in greater detail below, locking assemblies 19 (FIG. 3) may be mounted on the frame of the modular building unit 11 to facilitate stacking the modular building units on top of each other and in correct alignment locking the stacked modular building units together. In the illustrated embodiments, the locking assemblies are fixedly attached, such as by welding, bolting, etc. The locking assemblies become part of the modular building and may be said to be “integrated” into the modular building unit.
Referring to FIGS. 1A and 1B, each wall assembly 15 comprises a top cross member or beam 21, a bottom cross member or beam 23, and a plurality of first vertical members or studs 25 extending between the top and bottom cross members. The top and bottom cross members 21, 23 extend parallel to each other, and the first studs 25 extend parallel to each other. The first studs 25 are spaced inward from longitudinal ends of the top and bottom cross members 21, 23 such that the first studs extend from a top surface of the bottom cross member to a bottom surface of the top cross member. A second vertical member 27 is disposed on one of the longitudinal ends of the top and bottom cross members 21, 23 and extends generally from a bottom surface of the bottom cross member to a top surface of the top cross member. The second vertical members 27 extend parallel to the studs 25. In the illustrated embodiment, each of the top and bottom cross members 21, 23 and the second vertical members 27 have a hollow rectangular shape (built up box member or HSS tube section). However, the members could have other configurations without departing from the scope of the disclosure. For example, the members could comprise cold form steel sections. Moreover, structural members could be positioned diagonally within the building unit to create cross bracing.
Referring to FIGS. 1A and 1C, the ceiling assembly 13 comprises a plurality of parallel cross members or beams 33 spaced apart along a length of the ceiling assembly, and a plurality of parallel horizontal ceiling members or rafters 35 extending between the cross members. In other embodiments (not shown), the rafters 35 may extend parallel to the cross members 33. In particular, first cross members 33A extend across the ceiling assembly 13, and first ceiling members or rafters 35A extend between the first cross members. In the illustrated embodiment, one of the first cross members 33A defines an end of the ceiling assembly 13, and the other first cross members define intermediate portions of the ceiling assembly. A second cross member 33B defines an opposite end of the ceiling assembly 13. Second ceiling members or rafters 35B extend between the second cross member 33B and one of the first cross members 33A. Third ceiling members or rafters 35C define the outermost ceiling members on the ceiling assembly 13 and extend between the first cross members 33A and between the second cross member 33B and one of the first cross members. In the illustrated embodiment, each of the first and second cross members 33A, 33B and the third rafters 35C have a hollow rectangular shape (built up box member or HSS tube section), and each of the first and second rafters 35A, 35B has a channel shape. Again, other configurations of the cross members 33 and rafters 35 are contemplated.
Referring to FIGS. 1A and 1D, the floor assembly 17 comprises a plurality of parallel cross members/bars 41 spaced apart along a length of the ceiling assembly, and a plurality of parallel horizontal floor members or joists 43 extending between the cross members. In other embodiments (not shown), the joists 43 may extend parallel to the cross members 41. The floor assembly 17 is configured substantially similarly to the ceiling assembly 13. In particular, first cross members 41A extend across the floor assembly 17, and first floor members or joists 43A extend between the first cross members. In the illustrated embodiment, one of the first cross members 41A defines an end of the floor assembly 17, and the other first cross members define intermediate portions of the floor assembly. A second cross member/bar 41B defines an opposite end of the floor assembly 17. Second floor members or joists 43B extend between the second cross member 41B and one of the first cross members 41A. Third floor members/bars or joists 43C define the outermost floor members on the floor assembly 17 and extend between the first cross members 41A and between the second cross member 41B and one of the first cross members. In the illustrated embodiment, each of the first and second cross members 41A, 41B and the third joists 43C have a hollow rectangular shape (built up box member or HSS tube section), and each of the first and second joists 43A, 43B has a channel shape. The members could still have other configurations without departing from the scope of the disclosure.
Referring to FIGS. 1A, 4, and 5, the wall assemblies 15 are attached to the ceiling assembly 13 along the sides of the ceiling assembly by connection plates 45. The connection plates 45 are fixedly attached to the cross members 21, 23 of the wall assemblies 15. For example, the connection plates 45 may be welded to the cross members. However, the connection plates 45 may be attached to the wall assemblies 15 by other means. In the illustrated embodiment, each connection plate 45 comprises a generally rectangular plate member defining a plurality of fastener holes.
Referring to FIGS. 2-4, the locking assemblies 19 mounted on the modular building units 11 facilitate stacking the modular building units on top of each other (via guiding features) in consistent and correct alignment, and locking the stacked modular building units together. Thus, a building comprising multiple modular building units 11 attached together can be quickly and securely erected using only the components on the modular building units 11 and any tools needed to actuate the components on the modular building unit. In the illustrated embodiment, a locking assembly 19 is located at each end portion of a wall assembly 15 of the modular building unit 11, and also roughly intermediate the end portions. Therefore, six locking assemblies 19 are provided for each modular building unit 11. However, other numbers or locking assemblies 19 can be provided without departing from the scope of the disclosure. To stack a modular building unit 11 on top of another modular building unit 11, a first (top) modular building unit is lifted above a second (bottom) modular building unit and lowered down toward the second modular building unit. In one embodiment, lifting shackles 47 (FIG. 4) can be attached to the locking assemblies 19 on the top modular building unit 11 to assist in lifting the top modular building unit above the bottom modular building unit 11 and lowering the top modular building unit onto the bottom modular building unit. Shackles 47 may be a component of lifting tackle that is used to lift the top modular building unit 11. As the top modular building unit 11 is being contacted with the bottom modular building unit 11, the locking assemblies 19 of the bottom modular building unit interact with the top modular building unit to first locate the top modular building unit relative to the bottom modular building unit. During the lowering and locating steps, the locking assemblies 19 on the top modular building unit 11 are in an unlocked configuration (FIG. 14A). As will be explained in greater detail below, once the top modular building unit 11 is properly seated on the bottom modular building unit 11, the locking assemblies 19 on the top modular building unit can then be operated to move from the unlocked configuration to a locked configuration (FIGS. 14B-14D) whereby the locking assemblies on the top modular building unit lock with a respective locking assembly on the bottom modular building unit to lock the top modular building unit to the bottom modular building unit. Multiple modular building units 11 can be stacked on top of each other using this procedure. Moreover, other ways of lifting the modular building units 11 can be employed (e.g., lifting techniques that do not employ shackles 47) within the scope of the present invention. Further, the present disclosure has particular application to connection of modular building units that are stacked on one another. However, aspects of the invention are applicable to building units placed side-by-side or end-to-end. Thus, the term “adjoining relation” used herein broadly refers to stacking, placing side-by-side and placing end-to-end.
Referring to FIGS. 1A, 2, 5, and 6, each locking assembly 19 comprises a guide sleeve 51 extending from the top cross member 21 of one of the wall assemblies 15 to the bottom cross member 23 of the wall assembly. In the illustrated embodiment, the guide sleeve 51 extends, at least partially, through the top and bottom cross members 21, 23 such that a channel 53 extending through the guide sleeve opens at a top of the top cross member and below a top of the bottom cross member providing a passage extending between the top and bottom cross members of the wall assembly 15. Openings 54 (FIG. 12) in a bottom surface of the bottom cross member 23 are aligned with the channel 53 extending through the guide sleeve 51 to provide a passage from the top of the bottom cross member, through the bottom cross member, and to the bottom of the bottom cross member. In the illustrated embodiment, each of the guide sleeves 51 have a hollow rectangular shape (built up box member or HSS tube section). However, the guide sleeves 51 could still have other configurations without departing from the scope of the disclosure.
Referring to FIGS. 3, 4, and 7-9, an alternative embodiment of a guide sleeve is generally indicated at 51′. The guide sleeve 51′ comprises a top guide sleeve section 51A′ extending downward from the top cross member 21 toward the bottom cross member 23, and a bottom guide sleeve section 51B′ extending from the bottom cross member upward toward the top cross member. The guide sleeve sections 51A′, 51B′ extend only part way between the top and bottom cross members 21, 23 such that a gap is formed between a bottom of the top guide sleeve section and a top of the bottom guide sleeve section. The top guide sleeve section 51A′ also extends through the top cross member 21 such that a channel 53A′ extending through the top guide sleeve section opens at a top of the top cross member at a top of the channel, and opens below the top cross member at a bottom of the channel. The bottom guide sleeve section 51B′ extends through the bottom cross member 23 such that a channel 53B′ extending through the bottom guide sleeve section opens below a top of the bottom cross member 23 at a bottom of the channel, and opens above the top of the bottom cross member at a top of the channel. Therefore, the top and bottom guide sleeve sections 51A′, 51B′ of the guide sleeve 51′ together provide at least a part of a passage extending along the wall assembly 15 from the top of the wall assembly to bottom of the wall assembly. It will be understood that the guide sleeve 51′ may have other configurations within the scope of the present invention. For example and without limitation, in some embodiments (not shown) upper sleeve section 51A′ may not hang down from top cross member 21, or may be entirely removed. Still other embodiments may include guide sleeves of different configurations.
Referring to FIGS. 4, 10, 11, and 15A-17, each locking assembly 19 further comprises a key box 55 mounted on top of the top cross members 21 of the wall assemblies 15, and a locking bar 57 (broadly, a locking extension) mounted on the top cross member and extending downward into an associated guide sleeve 51, 51′ on the wall assembly. The key box 55 comprises a hollow trapezoidal housing 59 including a top surface 61, a pair of opposing angled side surfaces 63, a pair of opposing angled end surfaces 65, and a bottom surface 67. In one embodiment, the housing 59 may comprise a casted body. The housing 59 has a length L extending between the end surfaces 65, a width W extending between the side surfaces 63, and a height H extending between the bottom surface 67 and the top surface 61 (FIG. 15B). The key box 55 is mounted on the frame of the modular building unit 11 such that the bottom surface 67 of the housing 59 is directly attached to a top surface of one of the top cross members 21 of a wall assembly 15. For example, the housing 59 may be welded to the top cross member 21. However, the key box 55 could be attached to the modular building unit 11 by other means without departing from the scope of the disclosure. For example and without limitation, the key box 55 could be attached to one of the vertical members 27 (not shown). The construction of the key box 55 and its connection to the modular building unit 11 is sufficiently strong so that the entire modular building unit can be lifted up using the key boxes. As will be explained in greater detail below, the trapezoidal shape of the housing 59 facilitates locating a top modular building unit 11 on a bottom modular building unit 11 having a key box 55 (FIGS. 12 and 13) by using the angled side surfaces 63 and angled end surfaces 65 to guide the key box 55 into the opening 54 in a bottom cross member 23 on the top modular building unit. In one embodiment, the length L of the housing 59 is between about 6 inches and about 9 inches, the width W is between about 2 inches and about 5 inches, and the height H is between about 3 inches and about 7 inches. In one embodiment, the length L is about 9 inches, the width W is about 3.125 inches, and the height H is about 5.5 inches. It will be understood that the housing 59 could have other dimensions without departing from the scope of the disclosure. Broadly, the housing 59 is sized to be received in the openings 54 in the bottom cross members 23 of the wall assemblies 15. In other embodiments not illustrated herein, the housing 59 could be received by another component of the modular building unit 11, such as one of the vertical members 27.
Referring to FIGS. 15A-17, the housing 59 includes a top opening 69 formed in the top surface 61, a pair of first side openings 71 formed in respective side surfaces 63, a pair of second side openings 73 formed in respective side surfaces 63, and a bottom opening 75 formed in the bottom surface 67. The first side openings 71 are offset from each other such that a center C of one of the first side openings is located closer to a first end of the housing 59, and a center C of the other of the first side openings is located closer to a second end of the housing. However, the first side openings 71 are sized such that at least a portion of the first side openings overlap each other generally at a midpoint M of the housing 59 along the length L of the housing. In the illustrated embodiment, the first side openings 71 have a generally rectangular shape, and the second side openings 73 have a generally circular shape. The second side openings 73 are also offset from each other along the length L of the housing 59. Thus, each side surface 63 of the housing 59 includes a first side opening 71 generally on one end of the side surface and a second side opening 73 generally on the other end of the side surface. In the illustrated embodiment, the top opening 69 has a generally oval or oblong shape including a center portion 77 extending along the sides of the opening having rounded or convex surfaces providing an increased width section of the top opening. The ends of the opening 69 are also rounded. However, the openings 69, 71, 73, 75 could have other shapes without departing from the scope of the disclosure. Other arrangements and numbers of openings in the housing 59 could be employed. Each of the openings 69, 71, 73, 75 communicates with an interior space 79 of the housing 59. As such the top opening 69, the interior space 79 in the housing 59, and the bottom opening 75 provide a passage through the key box 55 from a top of the box to a bottom of the box.
Referring to FIG. 18, a key box of another embodiment is generally indicated at 55′. The key box 55′ is substantially similar to the key box 55 of the previous embodiment. However, top opening 69′ has a generally rectangular shape, and the key box is free of second side openings in the side surfaces 63′. Additionally, the key box 55′ comprises a plated body. The key box 55′ is otherwise constructed and operates in substantially the same manner as the key box 55 of the previous embodiment.
Referring to FIG. 19, a key box of another embodiment is generally indicated at 55″. The key box 55″ is similar to key box 55, 55′ of the previous embodiments. However, the key box 55″ includes side openings 71″ that are centered on side surfaces 63″ of the key box. Additionally, the housing 59″ does not include the rounded top edges of the previous key boxes. In some embodiments, the housing may have only one full length side (as opposed to two as shown) with other sides truncated, shortened, or otherwise not equivalent in length. The key box 55″ otherwise functions substantially the same as the key boxes 55, 55′ of the previous embodiments.
Referring to FIGS. 20-22, the locking bar 57 includes a shaft 81 and a key 83 mounted on an end of the shaft. For example, the key 83 (broadly, “locking element”) may be mounted on a bottom end of the shaft 81. The key 83 extends laterally from the shaft 81 in a first direction and in a second direction opposite the first direction. In the illustrated embodiment, the key 83 extends orthogonally from the shaft 81 in the first and second directions. As such, the shaft 81 and key 83 form a generally T-shape. However, the key 83 could extend laterally from the shaft 81 in a single direction such that the shaft and key form a generally L-shape. The key 83 could also extend from the shaft 81 at other angles without departing from the scope of the disclosure. In the illustrated embodiment, the shaft 81 comprises an elongate rod and the key 83 comprises a cuboidal block or plate. In one embodiment, the shaft 81 comprises a ⅞″ steel rod, and the key 83 comprises a 1.125″×2.5″ steel block. However, the shaft 81 and key 83 could be made of other materials and have other sizes and configurations without departing from the scope of the disclosure. For example, the shaft 81 could comprise a 1 inch or ¾ inch diameter rod. The shaft 81 is threaded along at least a top section 85 of the shaft, and is threadably engaged with a nut 87 received around the top section of the shaft. A washer 89 is also received around the shaft 81 and is located below the nut. In another embodiment, the shaft 81 may have a clinching mechanism or compression cap (not shown). The shaft 81 may have other shapes (not shown), such as having an end opposite the key 83 formed with a dimensionally angled bend and in one embodiment the end of the shaft is formed as a J-hook.
Referring to FIGS. 4 and 10, the locking bar 57 is mounted on the top cross member 21 of a wall assembly 15 and extends through the top cross member and downward from the top cross member into the guide sleeve 51, 51′. The washer 89 is configured to seat against the top surface of the top cross member 21. During use to lock a top modular building unit 11 to a bottom modular building unit 11, the nut 87 engages a top surface of the washer 89 and is rotatable to cause the shaft 81 to move relative to the nut via the threaded engagement between the nut and shaft. Initially, a removable tube 91 (broadly, a spacer) (FIG. 4) may be disposed between the washer 89 and the nut 87 to space the nut from the washer. This also spaces the key 83 at the bottom of the shaft 81 from the bottom of the wall assembly 15 so that when the modular building unit 11 is mounted on top of another modular building unit, the key does not prematurely engage the bottom modular building unit or a locking assembly 19 on the bottom modular building unit (FIG. 14A), and become damaged and possibly inoperable.
Referring to FIGS. 4 and 13-14B, the locking assemblies 19 are operable to lock a top modular building unit 11 onto a bottom modular building unit 11. Initially, the top modular building unit 11 is raised above the bottom modular building unit 11 (FIG. 2). In particular, pins 93 of the lifting shackles 47 are inserted into one of the second side openings 73 in the housings 59 of the key boxes 55 of the locking assemblies 19 of the top modular building unit. The locations and sizes of the second side openings 73 provides sufficient space for the lifting shackles 47 to be inserted into the interior spaces 79 of the housings 59 without interfering with the locking bars 57. A lifting device (not shown) can then be attached to handles 95 of the lifting shackles 47 to lift the top modular building unit 11 above the bottom modular building unit 11. The lifting device can then be used to lower the top modular building unit 11 onto the bottom modular building unit 11 so that the key boxes 55 of the locking assemblies 19 of the bottom modular building unit are received in respective openings 54 (FIG. 14A) in the bottom of the bottom cross members 23 of the wall assemblies 15 of the top modular building unit 11. The configuration of the key boxes 55 facilitates stacking the top modular building unit 11 on the bottom modular building unit. In the illustrated embodiment, the side walls 63 and end walls 65 taper inwardly from the bottom of the key box to the top of the key box. The narrower top side of the key box 55 can more easily enter the opening 54 in the bottom of the bottom cross member 23, as the narrower top is smaller than the opening. In other words, there can be some misalignment of the top modular building unit 11 with the bottom modular building unit, and the key box 55 will still be able to enter the opening 54. Once the key box 55 starts in the opening 54, the tapering sides of the key box can engage the perimeter of the opening and guide the top modular building unit 11 into proper alignment with the bottom modular building unit.
The reception of the key box 55 within the bottom cross member 23 of the top building unit can facilitate transfer of horizontal forces through multiple modular building units. In practice, the modular building units would be arranged both one on top of the other, but also next to other modular building units stacked on each other to form a building. In practice, building units that are side-by-side can be connected at the ceiling, but not at the floor. A lateral load applied to a top building unit can still be transferred to the adjacent top building unit. At the side on the floor of the first top building unit, the lateral load would pass from the first top building unit to the first bottom unit by virtue of the fit of the key box 55 within the bottom cross member 23 of the top building unit. The first bottom building unit is connected at its ceiling to a second bottom building unit located to the side of the first. The lateral force transferred from the first top building unit to the first bottom building unit can be transferred to the second bottom building unit through its connection with the first bottom building unit. A component of that lateral force can then be transferred from the second bottom building unit to a second top building unit by virtue of the key box rigidly attached to the second bottom building unit and tightly received in a bottom cross member of the second top building unit. In this way substantial lateral stability of a building constructed from modular building units may be achieved without requiring welding or otherwise attaching plates to the horizontally adjacent building units.
The removable tubes 91 of the locking assemblies 19 of the top modular building unit 11 can then be removed causing the locking bars 57 to drop into place such that the washers 89 engage the top surfaces of the top cross members 21 of the wall assemblies 15. This will also position the keys 83 on the locking bars 57 within the interior space 79 of the key boxes 55 on the bottom modular building unit 11.
Referring to FIGS. 10, 12, 13, and 14B-14D, a tool (e.g., a wrench) can be inserted either through the top opening 69 in the housing 59 of the key boxes 55 on the top modular building unit 11 or through the one of the first side openings 71 to engage the nuts 87 in the housings 59 to rotate the nuts. The increased width sections 77 in the top openings 69 allow for a head of a tool sized to engage the nut 87 to be inserted through the top openings and into the interior space 79 of the housings 59. The size of the first side openings 71 also permits a tool to be inserted through the sides 63 into the interior space 79 of the housings 59 to engage the nuts 87. Rotation of a nut 87 (i.e., clockwise rotation) causes the corresponding shaft 81 to rotate which in turn rotates the key 83 on the shaft within the interior space 79 of the key box 55 on the lower modular building unit 11. A mark or slot (not shown) on the shaft 81 is positioned on the shaft so that it may be observed by the installer so that the position of the key 83 is known as the shaft is rotated. In the instance where a slot is present in the shaft 81, it may also provide a location for engaging the shaft with a tool to rotate the shaft. Continued rotation of the key 83 in the key box 55 causes side surfaces 96 (FIGS. 20 and 22) of the key to engage side interior edges 97 (FIGS. 14C and 14D) of the first side openings 71 stopping further rotation of the key. In this position, a top surface 98 of the key 83 opposes top interior edges 99 of the first side openings 71 preventing the locking bar 57 from moving upward. The washer 89 prevents downward movement of the nut 87 on the shaft 81.
Therefore, rotation of the nut 87 on the shaft 81 causes upward movement of the shaft which causes the locking bar 57 to apply an upward clamping force to the key box 55 on the bottom modular building unit 11 thereby locking the locking assembly 19 on the top modular building unit 11 to the locking assembly 19 on the bottom modular building unit. In particular, the top surface 98 of the key 83 presses against the top interior edges 99 of the first side openings 71 in the key box 55 of the bottom modular building unit 11. Rotating the nuts 87 in all the locking assemblies 19 on the top modular building unit 11 in this manner fully locks the top modular building unit to the bottom modular building unit 11. Locking of the top modular building unit to the bottom modular building unit can be carried out with threading a component part of one locking assembly into the other locking assembly. While the individual locking assemblies 19 incorporate threaded components, the engagement between the locking assembly on the top modular building unit 11 with the locking assembly on the bottom modular building unit to connect the top modular building unit to the bottom modular building unit is free of any threaded engagements. Therefore, the connection between the modular building units 11 can be accomplished without the use of a threaded rod or bolt connection. Alternatively, a slot (not shown) in a top surface of the shaft 81 may be engaged by a tool to cause rotation of the shaft relative to the nut 87 causing the same clamping force to be applied by the locking bar 57 to the key box 55 on the bottom modular building unit 11. As a result, only one additional tool is needed to lock the top modular building unit 11 to the bottom modular building unit 11.
Referring to FIGS. 23-25, building units of another embodiment are generally indicated at 111 and 111′. As was described above for modular building unit 11, the modular building units 111, 111′ may be used in the modular construction of a building. For example, multiple assembled building units 111, 111′ may be stacked on top of each other to form a building. In the illustrated embodiment, a first, bottom building unit 111 comprises a plurality of column members 113 (only one is shown), and a plurality of beam members 115 (only one is shown) attached to the column members. In particular, a first column member 113A is attached to a first beam member 115A along one longitudinal side of the column member. In one embodiment, the first column member 113A is welded to the first beam member 115A. However, the first column member 113A can be attached to the beam member 115A by any suitable means without departing from the scope of the disclosure.
Alternatively, the bottom building unit 111 may include only a single beam member 115 or a single column member 113 without departing from the scope of the disclosure. As such, the bottom building unit 111 may comprise a single building component.
A second, top building unit 111′ may be stacked on top of the bottom building unit 111 and also comprises a plurality of column members 113′ (only one is shown), and a plurality of beam members 115′ (only one is shown) attached to the column members. It will be understood that the elements of the top building unit 111′ are given the same reference numerals as for the bottom building unit 111, with the addition of a prime. In particular, a first beam member 115A′ may be attached to a first column member 113A′. In one embodiment, the first beam member 115A′ is welded to the first column member 113A′. However, the beam members 115A′, and column members 113A′ can be attached by any suitable means without departing from the scope of the disclosure. It will be further understood that the top building unit 111′ may include only a single beam member 115′ or a single column member 113′ without departing from the scope of the disclosure. As such, the top building unit 111′ may comprise a single building component.
In the illustrated embodiment, each of the column members 113,113′ and beam members 115, 115′ of the building units 111, 111′ have a hollow rectangular shape (built up box member or HSS tube section). However, the members 113, 113′, 115, 115′ could have other configurations without departing from the scope of the disclosure. For example, the members 113, 113′, 115, 115′ could comprise cold form steel sections.
In one embodiment, the modular building units 111, 111′ are erected in an assembly plant and other components (not shown) are attached to the building units to create the building unit for installation at the construction site. In some circumstances, the building units may have essentially everything needed for a finished room or rooms prior to being assembled with other building units. However, for simplicity only portions of the frames of the building units are shown and described herein. Moreover, it will be understood that the frames can themselves be considered “modular building units,” as can any unit with any increment of finishing from the bare frame to the fully finished room(s). The level of finish applied to the building units can be different at the time the building units are connected together to form a building. Moreover, the person of ordinary skill in the art will appreciate that the configuration of the frame of the building units 111, 111′ may be other than described (often as dictated by the requirements of a particular building project) within the scope of the present invention. For instance, the modular building units 111, 111′ may include only a single building component.
Referring to FIGS. 24-26, locking assemblies 119, 119′ may be mounted on the building units 111,111′ to facilitate stacking the building units on top of each other in consistent and correct alignment, and locking the stacked building units together. Thus, a building comprising multiple building units 111, 111′ attached together can be quickly and securely erected using only the components on the building units 111, 111′ and any tools needed to actuate the components on the building units. In the illustrated embodiment, a locking assembly 119 is located on top of the first column member 113A and first beam member 115A of the bottom building unit 111. It will be understood that that additional locking assemblies 119 may be located at other locations on the building units 111, 111′ to suitably and securely lock the building units together.
To stack a building unit 111′ on top of another modular building unit 111, a top building unit is lifted above a bottom building unit and lowered down toward the bottom building unit. As the top building unit 111′ is lowered to a position adjacent the bottom building unit 111, the locking assemblies 119 of the bottom building unit are configured to interact with the top building unit to first locate the top building unit relative to the bottom building unit. During the lowering and locating steps, the locking assemblies 119′ on the top building unit 111′ are in an unlocked configuration. Once the top building unit 111′ is properly seated on the bottom building unit 111, the locking assemblies 119′ on the top building unit can then be operated to move from the unlocked configuration to a locked or coupled configuration whereby the locking assemblies on the top building unit lock with a respective locking assembly on the bottom building unit to lock the top building unit to the bottom building unit.
Referring to FIGS. 26-32, each locking assembly 119 comprises a key box 155 mounted on top of the bottom building unit 111, and a locking extension 157 connected to the key box such that the extension is extendable downward from the key box past a bottom of the building unit. The key box 155 comprises a locking fixture 159 and a pair of support plates 161 attached to opposite sides of the locking fixture. In one embodiment, the support plates 161 are welded to the locking fixture 159. However, the support plates 161 can be attached to the locking fixture in any suitable manner. The key box 155 is mounted on the building units 111 such that a bottom of the key box is directly attached to a top surface of the building unit. For example, the locking fixture 159 and support plates 161 may be bolted to the column/beam members 113A, 115A as explained below. However, the key box 155 could be attached to the building units 111 by other means without departing from the scope of the disclosure. For example, and without limitation, the key box 155 could be welded to the building unit 111. Further, as will be explained in greater detail below, the angled shape of the support plates 161 facilitates locating the top building unit 111′ on the bottom building unit 111 having one or more key boxes 155 by using the angled edge surfaces of the angled support plates 161 to guide the key boxes 155 into openings 154′ in the first beam members 115A′ on the top building unit. Thus, the key boxes 155 are sized to be received in the openings 154′ in the first beam members 115A′ of the top building unit 111′ to at least initially position the top building unit on the bottom building unit 111.
Referring to FIG. 33, the locking fixture 159 comprises a bent plate member including a center portion 162, a pair of leg 164 extending from opposite ends of the center portion, and a pair of feet 166 extending from respective legs. In the illustrated embodiment, the feet 166 extend in a common horizontal plane, and the legs 164 extend upward at an angle from the feet to the center portion 162. Therefore, the center portion 162 is raised above the feet 166 by a distance equal to a height of the legs 164. The center portion 162 extends generally parallel to the feet 166 and defines an opening 168 shaped and arranged to receive and lock with locking extensions 157 as will be explained in greater detail below. In the illustrated embodiment, the opening 168 comprises a generally circular center section 170 and a pair of oblong side sections 172 extending from opposite sides of the circular center section. The center section 170 has a cross-section dimension (i.e., diameter) that is greater than a cross-sectional dimension (i.e., width) of the side sections 172. In particular, a cross-sectional dimension of the center section 170 extending orthogonally between opposite longitudinal sides of the center portion 162, is larger than corresponding cross-sectional dimensions of the side sections 172. The feet 166 may also define openings 174 for receiving fasteners for bolting the locking fixture, and thus the key box 155, to the building unit 111.
Referring to FIGS. 26-28, the locking extensions 157 each include a cable 181, 181′ and a first cable tie 183, 183′ (broadly, a key) mounted on a first (bottom) end of the cable. A second cable tie 189 is mounted to a second (top) end of the cable 181. The second cable tie 189 may be used to couple the cable 181 to the key box 155, and the first cable tie 183′ is configured to secure the cable to a key box on a different, lower building unit 111, as will be explained below. The first and second cable ties 183, 189 are sized such that a cross-sectional dimension of the cable ties is larger than a cross-sectional dimension the cable 181. As such, the first and second cable ties 183′, 189 define widened end portions of the locking extension 157. The widened end portions of the locking extension 157 are configured to retain the locking extensions to the key boxes 155, as further described hereinafter.
Each locking extension 157 is configured to be mounted on a respective locking fixture 159 and extend through an open bottom of the key box through openings in the first beam members 115A such that the locking extension extends below the first beam member. In one embodiment, the second cable tie 189 is sized such that it can be inserted through the center section 170 of the opening 168 in the locking fixture 159 from a bottom side of the locking fixture. For instance, the second cable tie 189 may have a cross-sectional dimension (i.e. diameter) that is slightly smaller than the cross-sectional dimension of the center section 170. The locking extension 157 is then moved laterally within the opening 168 to locate the cable 181 in one of the side sections 172 of the opening. The second cable tie 189 can then be seated on a top side of the center portion 162 of the locking fixture 159. Because the cross-sectional dimension of the second cable tie 189 is larger than the cross-sectional dimension of the side sections 172 of the opening 168, the second cable tie is prevented from falling back out through the opening.
Referring still to FIGS. 26-28, the locking assemblies 119, 119′ are operable to lock a top modular building unit 111′ onto a bottom building unit 111. Initially, the top modular building unit 111′ is raised above the bottom building unit 111 such as by a crane. The crane can then be used to lower the top modular building unit 111′ toward the bottom building unit 111 so that a bottom of the top building unit is positioned slightly above or generally at the location of the locking assemblies 119 on the bottom building unit. Once the top building unit 111′ is in position above the bottom building unit 111, the locking assemblies 119 will be generally aligned configuring the building units to be coupled together. In particular, a locking extension 157 of a locking assembly 119′ on the top building unit 111′ will be generally located adjacent a key box 155 of a locking assembly 119 on the bottom building unit. In this position, the first cable tie 183′ on the cable 181′ of the locking extension 157′ on the top building unit 111′ can be inserted into the center section 170 of the opening 168 in the key box 155 on the bottom building unit 111. The first cable tie 183′ can then be moved laterally to locate the cable 181′ in one of the side sections 172 not already occupied by a cable tie (i.e., not occupied by the second cable tie 189 of the locking extension 157 mounted on the key box 155). The first cable tie 183′ is then positioned opposite a bottom of the open side section 172 of the opening 168, and because the cross-sectional dimension of the first cable tie 183′ is larger than the cross-sectional dimension of the open side section 172, the first cable tie is prevented from being pulled back through the opening. Openings 190 in the support plates 161 of the key box 155 facilitate access of the first cable tie 183′ to move the cable 181′ into the open side section 172 of the opening 168. The openings 190 may also be used to receive a component (e.g., a shackle) of lifting tackle to lift the building unit 111.
The top building unit 111′ can then be lowered all the way down to the bottom building unit 111 so that the key boxes 155 of the locking assemblies 119 of the bottom building unit are fully received in respective openings 154′ (FIG. 24) in the bottom of the first beam members 115A′ of the top building unit 111′. The configuration of the key boxes 155 may also facilitate stacking the top building unit 111′ on the bottom building unit 111. In the illustrated embodiment, the support plates 161 taper inwardly from the bottom of the key box to the top of the key box. Thus, the narrower top side of the key box 155 can more easily enter the opening 154′ in the bottom of the top building unit 111′, as the narrower top is significantly smaller than the opening. In other words, there can be a large degree of misalignment of the top building unit 111′ with the bottom building unit 111, and the key box 155 will still be able to enter the opening 154′. In one embodiment, the top building unit 111′ is configured to be lowered onto the bottom building unit 111 whereby the key boxes 155 on the bottom building unit are received in the openings 154′ in the top building unit 111′ in a misaligned state. As the top building unit 111′ is lowered further, an edge margin of the opening 154′ engages one of the angled edge surfaces of the support plates. The angled edge surfaces act as inclined planes so that further downward movement of the top building unit 111′ results in simultaneous lateral movement of the top building unit. The lateral movement continues until the key box 155 is fully aligned with the opening 154, and is received into the opening. Thereafter, the key box 155 is configured to engage the top building unit 111′ to limit relative lateral movement between the building units for positioning the building units relative to each other.
The locking extension 157 of the locking assemblies 119′ on the top building unit 111′ can then be tensioned to remove any slack in cables 181′ so that the cable ties 183′, 189 apply a sufficient amount of force to the key boxes 155 of the building units 111 to secure the building units together. In one embodiment, a tensioning device such as a cable reel (not shown) can be used to tension the locking extension 157. However, any suitable tensioning device/mechanism may be used without departing from the scope of the disclosure. As a result, only one additional tool (i.e., a tensioning device) is needed to lock the top building unit 111′ to the bottom building unit 111. In one embodiment, the locking assemblies 119, 119′ are free of threaded components. Thus, the engagement between the locking assembly 119′ on the top building unit 111′ with the locking assembly 119 on the bottom building unit 111 to connect the top building unit to the bottom building unit is free of any threaded engagements. Therefore, the connection between the building units 111, 111′ can be accomplished without the use of a threaded rod or bolt connection.
In one embodiment, the second cable tie 189 may be considered a live end of the cable 181, and the first cable tie 183′ may be considered a dead end of the cable 181′. For instance, once the second cable tie 189 is connected to the key box 155, the cable 181 can be jacked to a desired tension to meet the load capacity needed for the building unit connection. Additionally, the first cable tie 183′ of the locking extension 157′ on the top building unit 111′ may be coupled to the key box on the bottom building unit 111 prior to locating the bottom of the top building unit adjacent to the top of the bottom building unit. In this instance, the locking extension 157′ may be tensioned as needed to guide movement of the top building unit 111′ into engagement with the bottom building unit 111.
When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
As various changes could be made in the above constructions, products, and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
OTHER STATEMENTS OF THE INVENTION
A1. A method of constructing a building comprising rotating a locking element of a locking assembly of a second modular building unit to lockingly engage a locking assembly of a first modular building unit.
A2. The method set forth in A1, further comprising removing a spacer from the locking assembly of the second modular building unit to cause the locking element to drop into the locking assembly of the first modular building unit.
A3. The method set forth in A1, further comprising rotating a nut of the locking assembly of the second modular building unit causing vertical movement of a shaft of the locking assembly of the second modular building unit so that the locking element of the locking assembly of the second modular building unit engages a key box of the locking assembly of the first modular building unit and applies a clamping force between the locking assemblies to lock the second modular building unit to the first modular building unit.
A4. The method set forth in A1, further comprising inserting a tool into an opening of the locking assembly of the second modular building unit to contact the locking assembly of the second modular building unit for rotating the locking element.
B1. A method of constructing a building comprising attaching a lifting tackle to a locking assembly of a second modular building unit, and lifting the second modular building unit above a first modular building unit using the lifting tackle attached to the locking assembly of the second modular building unit.
C1. A modular building unit assembly for use in constructing a building, the modular building unit assembly comprising a first modular building unit and a locking assembly mounted on the first modular building unit, the locking assembly being configured to position a second modular building unit located above the first modular building unit relative to the first modular building unit, and connect the first modular building unit to a locking assembly of the second modular building unit.
C2. The assembly set forth in C1, wherein the first modular building unit comprises a modular building frame.
C3. The assembly set forth in C3, wherein the locking assembly of the first modular building unit is configured to connect the first modular building unit to a third modular building unit located below the first modular building unit.
D1. A locking assembly comprising a key box having a generally trapezoidal shape.
E1. A locking assembly comprising a locking extension including an elongate bar, a key mounted on a first end portion of the bar, and a nut and a washer mounted on a second end portion of the elongate bar, wherein rotation of one of the nut and the bar causes movement of the bar relative to a first modular building unit.
E2. The locking assembly set forth in E1, wherein the nut is threadedly engaged with the bar.
E3. The locking assembly set forth in E1, further comprising a guide sleeve configured to be mounted on the first modular building unit to guide the movement of the elongate bar.
E4. The locking assembly set forth in E3, further comprising a spacer configured to be disposed between a top surface of the first modular building unit and the washer, a spacer spacing the washer from the top surface of the first modular building unit.
F1. A locking assembly comprising a locking extension including an elongate bar and a key mounted on a first end portion of the bar.
G1. A locking assembly comprising a locking extension including a cable and a cable tie mounted on the cable.
H1. A locking assembly comprising a locking body including a bent plate and a pair of support plates attached to the bent plate.
I1. A locking body for use in a locking assembly of a modular building unit comprises a lock box including a pair of openings formed in respective side walls, the openings being configured to receive lifting tackle for use in lifting the modular building unit when the locking body is mounted thereon.
J1. A building comprising a plurality of modular building units, each modular building unit including an integrated locking assembly locking a first modular building unit to a second modular building unit below the first modular building unit, the integrated locking assembly being configured to position a third modular building unit located above the first modular building unit relative to the first modular building unit, and connect the first modular building unit to a locking assembly of the second modular building unit.
J2. The building set forth in I1, wherein the locking assembly of the second modular building unit is mounted on top of the second modular building unit.
J3. The building set forth in I2, wherein locking assembly of the second modular building unit includes a locking body mounted on top of the second modular building unit, the locking body being configured to be received in an opening in a bottom of the first modular building unit.
K1. A method of constructing a building comprising:
- providing a first modular building unit;
- providing a second modular building unit including a locking assembly integrated into the second modular building unit;
- placing the first and second modular building units in adjoining relation to each other at a building site, said step of placing including engaging first structure of the first modular building unit with second structure of the second modular building unit so that the engagement of the first structure and the second structure guides movement of the first and second modular building units relative to each other.
L1. A building component for use in constructing a building, the building component comprising a first building component including an integrated locking assembly mounted on the building component, the integrated locking assembly being configured to position a second building component located above the first building component relative to the first building component, and connect the first building component to a locking assembly of the second building component.
L2. The building component set forth in K1, wherein the integrated locking assembly is configured to connect the first building component to a locking assembly of a third building component located below the first building component.
M1. A method of constructing a building comprising:
- providing a first building unit including a locking assembly integrated into the first building unit;
- providing a second building unit including a locking assembly integrated into the second building unit;
- placing the first and second building units in adjoining relation to each other at a building site; and
- engaging the locking assembly of the second building unit with the locking assembly of the first building unit to connect the second building unit to the first building unit, the engagement between the locking assemblies being free of a threaded connection.
M2. The method set forth in L1, wherein engaging the locking assemblies comprises engaging a locking extension of the locking assembly integrated with the second building with a locking body of the locking assembly integrated with the first building unit.
Patent Application
20220364354
