Patent Grant
10208483
The present disclosure relates generally to modular buildings. More particularly, the present disclosure relates to façades of modular units and methods of varying the design of façades of modular units.
Modular units are commonly used for constructing residential and industrial structures because they can be partially assembled/constructed remote from the building site and transported to the building site for assembly into a complete building structure. Typically in modular construction, glazing and glazing treatment are assembled to the modular unit off-site and delivered to the construction site as an integral unit. Due to the identical nature of modular units, the glazing and treatment also appear identical, giving the façade an overall simplistic, prefabricated aesthetic.
Accordingly, it would be advantageous to provide modular units that allow for greater flexibility in designing a façade having a more irregular, non-conventional appearance.
In one aspect of the present disclosure, a modular system is provided and includes a first pair of modular units to be disposed in a side-by-side orientation, and a second pair of modular units to be disposed in a side-by-side orientation and above or below the first pair of modular units. Each of the first pair of modular units includes a first modular frame and a first bracket. The first modular frame of each of the first modular units has a first front surface and a first lateral surface. The first brackets are disposed on the first front surface adjacent the first lateral surface. The first brackets are configured to be coupled to a façade trim and are spaced apart from one another a first distance. Each of the second pair of modular units includes a second modular frame and a second bracket. The second modular frame of each of the second modular units has a second front surface and a second lateral surface. The second brackets are disposed on the second front surface adjacent the second lateral surface and are configured to be coupled to a façade trim. The second brackets are spaced apart from one another a second distance, different than the first distance.
In embodiments, the first distance may be greater than the second distance.
In embodiments, the first and second distances may correspond to widths of a respective first and second façade trims.
In embodiments, the first façade trim may include first and second sections. The first section may be coupled to and extends outwardly from the first bracket of a first modular unit of the first pair of modular units. The second section may be coupled to and extend outwardly from the first bracket of a second modular unit of the first pair of modular units.
In embodiments, the second façade trim may include a first section and a second section. The first section may be coupled to and extend outwardly from the second bracket of a first modular unit of the second pair of modular units. The second section may be coupled to and extend outwardly from the second bracket of a second modular unit of the second pair of modular units.
In embodiments, the first pair of modular units may define a first mateline between the first lateral surfaces, and the second pair of modular units may define a second mateline between the second lateral surfaces. The first and second matelines may be aligned along a vertical plane when the first and second pairs of modular units are vertically stacked.
In embodiments, the first and second façade trims may be aligned along the vertical plane.
In embodiments, the first bracket of a first modular unit of the first pair of modular units may be configured to be coupled to a first curtain wall, and the first bracket of a second modular unit of the first pair of modular units may be configured to be coupled to a second curtain wall. The first and second curtain walls may be spaced apart from one another a third distance. The second bracket of a first modular unit of the second pair of modular units may be configured to be coupled to a third curtain wall, and the second bracket of a second modular unit of the second pair of modular units may be configured to be coupled to a fourth curtain wall. The third and fourth curtain walls may be spaced apart from one another a fourth distance, different than the third distance.
In embodiments, the first bracket of each of the first pair of modular units may have an L-shaped configuration.
In embodiments, the first bracket of each of the first pair of modular units may include a first portion extending along the first front surface, and a second portion extending perpendicularly from the first portion. The second bracket of each of the second pair of modular units may include a first portion extending along the second front surface, and a second portion extending perpendicularly from the first portion of the second bracket. The second portion of the first bracket may be longer than the second portion of the second bracket.
In another aspect of the present disclosure, a method of constructing a modular building is provided. The method includes providing the first and second pair of modular units, coupling a first façade trim to the first modular frame of each of the first pair of modular units via the first brackets, and coupling a second façade trim to the second modular frame of each of the second pair of modular units via the second brackets.
Some methods may further include vertically stacking the first pair of modular units on the second pair of modular units.
In some methods, vertically stacking may include aligning the first and second façade trims along a vertical plane.
Some methods may further include positioning the first pair of modular units in a side-by-side orientation, and positioning the second pair of modular units in a side-by-side orientation.
In some methods, the first and second distances may correspond to widths of the respective first and second façade trims, such that the widths of the first and second façade trims are different.
Some methods may further include coupling a first curtain wall to the first bracket of a first modular unit of the first pair of modular units, and coupling a second curtain wall to the first bracket of a second modular unit of the first pair of modular units, such that the first and second curtain walls are spaced apart from one another a third distance. A third curtain wall may be coupled to the second bracket of a first modular unit of the second pair of modular units, and a fourth curtain wall may be coupled to the second bracket of a second modular unit of the second pair of modular units, such that the third and fourth curtain walls are spaced apart from one another a fourth distance, different than the third distance.
Further details, advantages, and aspects of exemplary embodiments of the present disclosure are described in more detail below with reference to the appended figures.
As used herein, the term “about” or “approximately” applies to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure.
As used herein, the term “coupled” means either a direct mechanical connection between the components that are connected, or an indirect mechanical connection through one or more intermediary components.
As used herein, the term “mateline” refers to a central axis along which adjacent modular units are coupled to one another.
As used herein, the terms parallel and perpendicular are understood to include relative configurations that are substantially parallel and substantially perpendicular up to about + or −10 degrees from true parallel and true perpendicular.
Embodiments of the present disclosure are described herein with reference to the accompanying drawings, wherein:
Embodiments of the presently disclosed modular buildings and methods of construction are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views.
The present disclosure provides modular units that allow for the attachment of a variety of façade trims. Adjacent modular units of a first floor are disposed side-by-side, and adjacent modular units of a second floor are disposed side-by-side and above the modular units of the first floor. The adjacent modular units of each of the first and second floors have a connector for coupling to a unique façade trim. The connector of the adjacent modular units of the first floor defines a first horizontal gap, and the connector of the adjacent modular units of the second floor defines a second horizontal gap, that is greater in width than the first horizontal gap. Accordingly, the connectors of the first and second floors are configured to accommodate uniquely dimensioned façade trims. Due to the connectors allowing for the connection of uniquely dimensioned façade trims, the modular building assumes a less modular appearance. These and other features of the disclosed modular assemblies and their construction will be described in further detail herein.
Referring initially to
With reference to
With reference to
The first pair of modular units 12a, 12b respectively include first and second connectors, such as, for example, first and second brackets 26a, 26b. The first bracket 26a is coupled to the front surface 20a of the first modular frame 16a, and the second bracket 26b is coupled to the front surface 20b of the second modular frame 16b. Each of the brackets 26a, 26b has a respective first portion 28a, 28b and a second portion 30a, 30b extending perpendicularly from the first portion 28a, 28b, such that the brackets 26a, 26b assume an L-shaped configuration. In embodiments, the brackets 26a, 26b may assume any suitable configuration, such as, for example, v-shaped, I-shaped, or linear.
The first portion 28a of the first bracket 26a is attached to and extends horizontally along the front surface 20a of the first modular frame 16a at a location adjacent the lateral surface 18a of the first modular frame 16a. Similarly, the first portion 28b of the second bracket 26b is attached to and extends horizontally along the front surface 20b of the second modular frame 16b at a location adjacent the lateral surface 18b of the second modular frame 16b. The first portions 28a, 28b of the first and second brackets 26a, 26b are horizontally aligned. The second portion 30a of the first bracket 26a is configured to be coupled to both a first curtain wall 32a and a first section 14a of the first façade trim 14, and the second portion 30b of the second bracket 26b is configured to be coupled to both a second curtain wall 32b and a second section 14b of the first façade trim 14. The second portions 30a, 30b of the first and second brackets 26a, 26b are spaced horizontally from one another a first distance “d1” to provide a space to accommodate the first façade trim 14.
The first and second sections 14a, 14b of the first façade trim 14 are attached to the respective second portions 30a, 30b of the brackets 26a, 26b, and extend outwardly (e.g., perpendicularly) relative to the front surface 20a, 20b of the first and second modular frames 16a, 16b. Due to the horizontal spacing between the brackets 26a, 26b, the first façade trim 14 assumes a width that is substantially equivalent to the first distance “d1.” As will be described in further detail below, the width of the first façade trim 14, which is to be located on the first floor “A,” is different (e.g., smaller) than that of the second façade trim 24, which is to be located on the second floor “B,” thereby giving the modular building 10 a non-uniform appearance.
Each of the first and second modular units 12a, 12b further includes a curtain wall 32a, 32b attached to the respective first and second brackets 26a, 26b. The curtain walls 32a, 32b each include a mullion or vertical beam 34a, 34b attached to the second portion 30a, 30b of the respective bracket 26a, 26b, and glazing 36a, 36b extending from the mullion 34a, 34b. One or both of the curtain walls 32a, 23b may include a thermal break 38 disposed between the mullion 34b and the bracket 26b to decrease the thermal conductivity of the curtain walls 32a, 32b. The curtain walls 32a, 32b are horizontally spaced from one another due to the horizontal spacing between the brackets 26a, 26b.
With reference to
The third modular unit 12c has a third connector, such as, for example, a third bracket 26c, coupled to the front surface 20c of the modular frame 16c thereof, and the fourth modular unit 12d has a fourth connector, such as, for example, a fourth bracket 26d, coupled to the front surface 20d of the modular frame 16d thereof. Each of the brackets 26c, 26d has a respective first portion 28c, 28d and a second portion 30c, 30d extending perpendicularly from the first portion 20c, 20d, such that the 26c, 26d brackets assume an L-shaped configuration. In embodiments, the brackets 26c, 26d may assume any suitable configuration, such as, for example, v-shaped, I-shaped, or linear.
The first portion 28c of the third bracket 26c is attached to and extends horizontally along the front surface 20c of the third modular frame 16c at a location adjacent the lateral surface 18c of the third modular frame 16c. Similarly, the first portion 28d of the third bracket 26d is attached to and extends horizontally along the front surface 20d of the fourth modular frame 16d at a location adjacent the lateral surface 18d of the fourth modular frame 16d. The first portions 28c, 28d of the third and fourth brackets 26c, 26d are horizontally aligned. The first portion 28c, 28d of each of the third and fourth brackets 26c, 26d has a length that is greater than the length of the first portion 28a, 28d of each of the first and second brackets 26a, 26b, respectively. In embodiments, the first portion 28c, 28d of the third and fourth brackets 26c, 26d may be approximately two or more times the length of the first portion 28a, 28b of the first and second brackets 26a, 26b. In embodiments, the third and fourth brackets 26c, 26d may be substantially similar to the first and second brackets 26a, 26b, except for being rotationally offset approximately 90 degrees.
The second portion 30c of the third bracket 26c is configured to be coupled to both a third curtain wall 32c and a first section 24a of the second façade trim 24, and the second portion 30d of the fourth bracket 26d is configured to be coupled to both a fourth curtain wall 32d and a second section 24b of the second façade trim 24. The second portions 30c, 30d of the third and fourth brackets 26c, 26d are spaced horizontally from one another a second distance “d2” to provide a space for accommodating the second façade trim 24. The second distance “d2” of the spacing between the third and fourth brackets 26c, 26d is different than the spacing between the first and second brackets 26a, 26b. Specifically, the second distance “d2” may be greater than the first distance “d1,” such that the second pair of modular units 12c, 12d can accommodate a wider façade trim than the first pair of modular units 12a, 12b.
The first and second sections 24a, 24b of the second façade trim 24 are attached to the second portions 30c, 30d of the third and fourth brackets 26c, 26d, and extend outwardly (e.g., perpendicularly) relative to the front surface 20c, 20d of the third and fourth modular frames 16c, 16d. Due to the horizontal spacing between the brackets 26c, 26d, the second façade trim 24 assumes a width that is substantially equivalent to the second distance “d2.” The width of the second façade trim 24 of the second floor “B” is different (e.g., larger) than that of the first façade trim 14 of the first floor “A.” The first and second façade trims 14, 24 of the respective first and second floors “A,” “B” are aligned along a vertical plane so that when viewing the modular building 10, it is readily apparent that the façade trims 14, 24 of the first and second floors “A,” “B” are non-uniform.
The second pair of modular units 12c, 12d further includes respective third and fourth curtain walls 32c, 32d attached to the respective third and fourth brackets 26c, 26d. The curtain walls 32c, 32d each include a mullion or vertical beam 34c, 34d attached to the second portion 30c, 30d of the respective bracket 26c, 26d, and glazing 36c, 36d extending from the mullion 34c, 34d. One or both of the curtain walls 32c, 32d may include a thermal break 40 disposed between the mullion 34d and the bracket 26d to decrease the thermal conductivity of the curtain wall 32d. The horizontal spacing between the third and fourth brackets 26c, 26d results in a horizontal spacing between the third and fourth curtain walls 32c, 32d. Due to the second distance “d2” between the third and fourth brackets 26c, 26d being greater than the first distance “d1” between the first and second brackets 26a, 26b, the curtain walls 32c, 32d of the second pair of modular units 12c, 12d of the second floor “B” are horizontally spaced from one another a greater distance than the curtain walls 32a, 32b of the first pair of modular units 12a, 12b of the first floor “A.”
A method of constructing an alternating façade of a modular building 10 will now be described. A suitable number of modular units 12a, 12b, 12c, 12d are fabricated at an off-site facility and then delivered to the construction site as integral units consisting of the modular frame 16a, the first section 14a of the façade trim 14, and the curtain wall 32a. The number of modular units 12 manufactured for construction of the first and second floors “A,” “B” is selected based on the desired width of the modular building 10.
To construct the first floor “A” of the modular building 10, the first pair of modular units 12a, 12b is first manufactured at an off-site facility. To install the first pair of modular units 12a, 12b, the first section 14a of the first façade trim 14 is coupled to the first modular frame 16a via the first bracket 26a, and the second section 14b of the first façade trim 14 is coupled to the second modular frame 16b via the second bracket 26b. The first curtain wall 32a is positioned on the front surface 20 of the first modular frame 16a and coupled to the first bracket 26a and the first section 14a of the first façade trim 14. The second curtain wall 32b is positioned on the front surface 20b of the second modular frame 16b and coupled to the second bracket 26b and the second section 14b of the first façade trim 14.
To construct the second floor “B” of the modular building 10, the second pair of modular units 12c, 12d is first manufactured at an off-site facility. To install the second pair of modular units 12c, 12d, the first section 24c of the second façade trim 24 is coupled to the third modular frame 16c via the third bracket 26c, and the second section 24b of the second façade trim 24 is coupled to the fourth modular frame 16d via the fourth bracket 26d. The third curtain wall 32c is positioned on the front surface 20c of the third modular frame 16c and coupled to the third bracket 26c and the first section 24a of the second façade trim 24. The fourth curtain wall 32d is positioned on the front surface 20d of the fourth modular frame 16d and coupled to the fourth bracket 26d and the second section 24b of the second façade trim 24.
In some methods, the façade trims 14, 24 and/or the curtain walls 32a-d may be delivered to the construction site in a disassembled state from the modular frames 16a-d and be coupled to the modular frames 16a-d at the construction site.
At a construction site, the first pair of modular units 12a, 12b is positioned in a side-by-side orientation, such that their respective lateral surfaces 18a, 18b are adjacent one another, thereby forming a portion of the first floor “A.” The first and second sections 14a, 14b of the first façade trim 14 are fitted to one another along the mateline “M1.” The second pair of modular units 12c, 12d is positioned in a side-by-side orientation, such that their respective lateral surfaces 18c, 18d are adjacent one another, thereby forming a portion of the second floor “B.” The second pair of modular units 12c, 12b is vertically stacked on top of the first pair of modular units 12a, 12b, so that the first and second façade trims 14, 24 are aligned along a vertical plane that extends through each of the matelines “M1,” “M2” of the first and second floors “A,” “B.” Due to the first and second façade trims 14, 24 having different widths, when viewing the modular building 10, the first and second floors “A,” “B” appear non-uniform and non-modular. As shown in the illustrated embodiment, additional floors may be added to the modular building 10 by alternating between façade patterns of floors “A” and “B” so that the façade of the modular building 10 is non-uniform along its entire height.
It will be understood that various modifications may be made to the embodiments and methods disclosed herein. Therefore, the above description should not be construed as limiting, but merely as exemplifications of various embodiments and methods. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended thereto.
This application claims the benefit of and priority to U.S. Provisional Application No. 62/539,665, filed on Aug. 1, 2017, the entire contents of which are incorporated by reference herein.
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