ENGINEERED PRECISION CONSTRUCTION SYSTEM AND METHOD

Abstract

An engineered, modular structure includes multiple pods, which are mounted on a foundation subsystem and include structural systems. The pods are configured for fabrication off-site and transportation to a building site for placement on the foundation subsystem. Pod-pod connection assemblies include threaded rods configured for cinching adjacent pods together end-to-end in precise alignment.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to construction, and in particular to a prefabricated modular structure and a precision construction method.

2. Description of the Related Art

Conventional construction typically involves assembling various materials to form foundations, floors, walls, roofs, windows, doors and other components and systems. Conventional assembly techniques tended to be labor-intensive, with many of the components being cut to the necessary dimensions and fastened together on-site. For example, a typical wall includes structural framing, such as wooden studs in residential construction, insulation, sheathing, finished surfaces and trim. The various components are commonly sized on-site in order to achieve accurate fittings and connections.

Moreover, conventional construction tends to be time-consuming. For example, delays in receiving materials and completing critical path tasks can delay subsequent tasks and project completion. Another disadvantage with on-site construction relates to dimensional tolerance control and precision. Field conditions, including weather and material irregularities, tend to reduce accuracy and precision in finished structures. However, the present invention addresses such conventional construction shortcomings by providing engineered construction to relatively precise standards.

Engineered construction according to the present invention also accomplishes greater structural integrity. Still further, greater energy efficiency and weather resistance can be achieved to reduce air and water infiltration.

Heretofore there has not been available a system or method for engineered construction with the advantages and features of the present invention.

BRIEF SUMMARY OF THE INVENTION

The present invention generally provides an engineered precision construction system and method utilizing unique components and assembly procedures.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings constitute a part of this specification and include exemplary embodiments of the present invention illustrating various objects and features thereof.

FIG. 1 is a floor plan view of a residence embodying an aspect of the present invention, including multiple (four are shown) prefabricated modules or pods.

FIG. 2 is a perspective view of a framing system of a pod, particularly showing the foundation and a tie-down subsystem including a horizontal strap, a vertical strap and an inclined roof rafter strap.

FIG. 3 is an exploded, perspective view of a foundation subsystem.

FIG. 4 is a cross-sectional view of the foundation subsystem and a vertical strap.

FIG. 5 is a front view of the structural system and a perspective, detail view of a threaded rod extending through a vertical strap.

FIG. 6 is a perspective view of a pair of channel members aligned by an alignment subsystem and connected by a threaded rod.

FIG. 7 is a cross-sectional view showing a pair of channel members and the alignment subsystem, with the channel members separated.

FIG. 8 is another cross-sectional view showing the channel members clamped together in alignment.

FIG. 9 is a perspective view of a male connector of the alignment subsystem.

FIG. 10 is a perspective view of a ridge beam comprising telescoping inner and outer tubes for length-adjustment and showing an inclined roof rafter connected to the ridge beam.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

I. Introduction and Environment

As required, detailed aspects of the present invention are disclosed herein, however, it is to be understood that the disclosed aspects are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art how to variously employ the present invention in virtually any appropriately detailed structure.

Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, down, front, back, right and left refer to the invention as orientated in the view being referred to. The words, “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the aspect being described and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning.

II. Preferred Embodiment

Without limitation, the attached drawings show embodiments and aspects of the present invention. It is to be understood that while certain embodiments and/or aspects of the invention have been shown and described, the invention is not limited thereto and encompasses various other embodiments and aspects. For example, various configurations of structures can be constructed using the systems and methods of the present invention. Such structures can comprise residential, commercial, and industrial buildings.

FIG. 1 shows a floor plan of a residence 2 embodying an aspect of the present invention. Four modules or pods 4 are connected together to form the house 2. Each pod 4 is 12 feet wide, which complies with Department of Transportation (DOT) regulations for over-the-road transportation on a trailer. The pod length varies based on the finished, assembled floorplan configuration. Inter-pod abutting connections 6 are indicated by the connection lines 8 at 12 feet on center, as shown in FIG. 1. Larger structures can be assembled with additional modular pods 4. Internal room dimensions are also variable, depending on the desired floorplan configuration.

FIG. 2 shows a structural system 10 including a foundation subsystem 12 with a poured footing 14 and a precast footing 16 placed thereon, as shown in FIGS. 3 and 4. The precast footing 16 includes a base 18 with a footprint corresponding to the poured footing 14 and a foundation wall 22. A capillary break membrane is placed between the poured footing 14 and the precast footing base 18 to prevent the transfer of moisture therebetween, which could compromise the concrete integrity. Vertical dowel mechanical fastener pins 24 can be placed in pipes formed in the precast footing base 18 and extend into the poured footing 14 for securing and aligning the foundation subsystem 12 components.

The height of the foundation wall 22 is variable, depending on the depth of the frost line in the particular location. Full-height foundation walls 22 can be utilized to form basements. The poured and precast footings 14, 16 can include reinforcing bars 26 as necessary for structural integrity and building code compliance. The construction can include gravel around the footings 14, 16 and perforated foundation drainage pipes or tiles for conveying groundwater away from the foundation subsystem 12.

As shown in the. 4, a sill plate 28 is anchored on top of the foundation wall 22 and preferably comprises a material resistant to water, decay and insect infestation. Various treated lumber and composite structural material options are commercially available for this purpose.

FIG. 5 shows the foundation subsystem and a perforated vertical (wall) strap 30 extending upwardly therefrom and connected to an inclined roof rafter perforated strap 32. The vertical straps 30 are anchored to the sill plate 28 by base anchor straps 31. Three-quarter inch threaded rods 34 extend through the straps 30, 32 at predetermined, spaced locations.

As shown in FIG. 6, the pod-pod connections 6 are formed with pod-pod connection assemblies 36, which extends through adjacent C-channel members, 38. The C-channel members can be placed in the floor structure as floor joists, in the walls as studs, in the ceiling as ceiling joists and in the roof as rafters. Each connection assembly 36 includes a threaded rod 40 extending through sleeves 42, which are anchored in male and female connections 44, 46, mounted on connection plates 48, which are attached to respective C-channel members 38 by hex head screws 50. The male and female connections 44, 46 can also be attached with continuous welds 45, 47 respectively extending around their circumferences. The threaded rods 40 receive washers and nuts at each end, which enable tightening the pot-pod connection assemblies 36 to clamped configurations, as shown in FIG. 8. The tapered, frusto-conical configuration of the male connectors 44 engaging the female connectors 46 precisely aligns the adjacent C-channel members 38.

FIG. 10 shows a ridge beam 56 comprising outer and inner tubes 58, 60 telescopically interconnected for length adjustment. The tubes 58, 60 can be connected with mechanical fasteners, such as bolts with nuts 52 and washers 54, or welded together. A bent track 62 is mounted on the outer tube 58 and mounts a C-channel rafter 38.

III. Process of Fabrication

Components of the present invention can be prefabricated off-site for transportation to building sites. Prefabrication at manufacturing plants can produce greater precision, thus significantly improving the quality of the completed structures. Automated manufacturing equipment and techniques, including robotics and artificial intelligence (AI), can further improve efficiencies, precision, and performance.

Moreover, the fabrication process can accommodate a wide variety of materials, equipment and worker skills, with the goal of optimizing the performance of the finished structures as cost-effectively as possible. For example, skilled trades and licensed construction workers may be necessary for certain aspects of the construction process. Local building code and building official requirements can also be accommodated with appropriate fabrication processes.

Materials are preferably chosen for performance, including thermal efficiency, weather-resistance, durability and aesthetics. Without limitation, materials can be chosen for suitability for mass production processes.

It is to be understood that while certain embodiments and/or aspects of the invention have been shown and described, the invention is not limited thereto and encompasses various other embodiments and aspects.

Claims

1. A structure including: multiple pods with opposite sides and opposite ends;each said pod forming office of walls at said opposite sides thereof;a foundation subsystem including: a poured-in-place footing; a precast footing including a base and a foundation wall mounted on the poured-in-place footing; multiple mechanical fasteners fastening said poured footing to said precast footing base;each said pod including: a. a sill plate configured for mounting on and attachment to a respective foundation wall;b. multiple vertical C-channel studs connected to and extending upwardly from said sill plate;c. multiple horizontal floor joists connected to said sill plate and said studs and extending horizontally across said foundation subsystem;d. multiple ceiling joists connected to said studs and extending horizontally between the opposite of walls of said structure;e. multiple roof rafters connected to and extending upwardly and inwardly from said opposite walls; andf. a ridge beam connected to said rafters and comprising inner and outer telescopically-interconnected tubes adapted for adjusting said ridge beam length; andg. continuous straps connected to and extending along said C-channel studs and said see-channel roof rafters; andmultiple pod-pod connection assemblies each including: a. a sleeve extending through adjacent C-channel members;b. a threaded rod extending through said sleeve and across an interconnection of adjacent channel members;c. a pair of retaining nuts each threadably received on said threaded rod on a respective side of said connection;d. a male connector mounted on one of said adjacent C-channel members and including a tapered portion;e. a female connector mounted on the other of said adjacent C-channel members and including a receiver configured to receive a respective male connector; andf. said tapered portions of said male connectors adapted for aligning said male and female connectors upon tightening said retaining nuts.