CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit under 35 U.S.C. § 119(e) of Canadian patent application no. 2,895,868 which was filed on Jun. 30, 2015. The entirety of the aforementioned application is herein incorporated by reference.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to the field of modular structures for a building. More specifically, the present invention relates to a kit for a modular building system and a modular building assembled therefrom.
BACKGROUND
Existing modular construction systems for assembly from pre-manufactured elements are generally cubic or parallelepiped and result from assembly of different partitions that are made, for example, from concrete. Such systems are different to transport due to their weight and size, and often offer poor aesthetics.
Moreover, such known modular construction systems also do not provide easy disassembly or allow reuse of materials of after disassembly. Moreover, such modular construction systems do not offer easy of reconfiguration of the building, such as adding a storey or a room to the assembled building.
BRIEF SUMMARY OF THE INVENTION
It would thus be highly desirable to be provided with a system or method that would at least partially address the disadvantages of the existing technologies.
The embodiments described herein provide in one aspect a kit for a modular building system comprising a joist assembly having a pair of oppositely facing beam members and a joist supporting member being partially pinched between the pair of oppositely facing beam members and defining a gap therebetween along a lengthwise direction thereof, at least one supported member, and at least one connector comprising a retaining portion for retaining the supported member and a retained portion insertable into the gap to engage the joist assembly.
The embodiments described herein provide in another aspect a connector for a modular building system. The connector includes a body portion, a first leg member extending in a first direction from the body portion and being engageable with a supported stud and at least one second leg member extending in a second direction from the body portion and being engageable with a joist assembly, whereby, upon assembly, the supported stud is supported by the connector and the connector is further supported by the joist assembly.
The embodiments described herein provide in yet another aspect a connector for a modular building system. The connector includes a retaining portion being engageable to an end of the blocking member, a retained portion having a supported sub-portion extending longitudinally from the retaining portion and at least one leg sub-portion extending downwardly from a distal end of the supported sub-portion and being engageable with a joist assembly.
The embodiments described herein provide in yet another aspect a kit for a modular wall system having a first retaining member, a second retaining member and a firs thermal bridge breaking member. The first retaining member includes a first sidewall, a second sidewall, and a bottom wall defining together a slot for retaining a first insulating panel, the first retaining member further includes gripping strips extending from the first sidewall and defining a groove. The second retaining member also includes a first sidewall, a second sidewall, and a bottom wall defining together a slot for retaining a second insulating panel, the second retaining member further including gripping strips extending from the first sidewall and defining a groove. The first thermal bridge breaking member includes a body, a first tongue member extending from a first side of the body and a second tongue member extending from a second side of the body, the first tongue member being insertable into the groove of the first retaining member and the second tongue member being insertable into the groove of the second retaining member.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, advantages and features will become more apparent upon reading the following non-restrictive description of embodiments thereof, given for the purpose of exemplification only, with reference to the accompanying drawings in which:
FIG. 1a illustrates a perspective view of a joist supporting member of a joist assembly according to one example embodiment;
FIG. 1b illustrates the perspective view of the joist supporting member with concealed elements shown in stippled lines;
FIG. 2 illustrates a rear perspective view of the joist supporting member according the example embodiment;
FIG. 3 illustrates perspective view of a partially assembled joist assembly according to one example embodiment;
FIG. 4 illustrates a perspective view of an assembled joist assembly according to one example embodiment;
FIG. 5 illustrates a perspective view of a partially assembled modular building system having a joist assembly supported by a supporting stud according to one example embodiment;
FIG. 6 illustrates a perspective view of a partially assembled modular building system having a plurality of joist assemblies and supporting/supported studs according to one example embodiment;
FIG. 7 illustrates a perspective view of a partially assembled modular building system of FIG. 6, further comprising bracing members;
FIG. 8 illustrates a perspective view of a double-ended connector according to one example embodiment;
FIG. 9a illustrates a side elevation view of a partial assembly of the double-ended connector with a joist assembly according to one example embodiment;
FIG. 9b illustrates a perspective view of a partial assembly of the double-ended connector with a joist assembly according the example embodiment;
FIG. 10 illustrates a perspective view of a modular building system during an intermediate step of assembling a supported stud to a joist assembly according to one example embodiment;
FIG. 11 illustrates a perspective view a plurality of hanger connectors according to one example embodiment;
FIG. 12 illustrates a perspective view of an engagement of the hanger connectors;
FIG. 13 illustrates a perspective view of a partially assembled modular building system having a joist assembly and a pair of blocking members according to one example embodiment;
FIG. 14 illustrates a perspective view of the partially assembled modular building system of FIG. 13 showing concealed elements in stippled lines.
FIG. 15 illustrates a perspective view of an interaction of a joist supporting member, first and second hanger connectors and a double-ended connector according to one example embodiment;
FIG. 16 shows the interaction of FIG. 15 with concealed elements shown in stippled lines;
FIG. 17a illustrates a perspective view of a partially assembled modular building system having a joist assembly supporting a supported stud and a pair of blocking members according to one example embodiment;
FIG. 17b shows the partially assembled modular building system of FIG. 17a with concealed elements shown in stippled lines;
FIG. 18 illustrates a perspective view of a partially assembled building s system having a plurality of interconnected joist assemblies, studs and blocking members according to one example embodiment;
FIGS. 19 and 20 illustrate perspective views of a partially assembled building system having a joist assembly supporting a stud and a plurality of flooring members according to one example embodiment;
FIGS. 21 and 22 illustrate a perspective view of a partially assembled building system having top flooring members supported over sub-flooring members according to one example embodiment;
FIG. 23 illustrates a perspective view of a partially assembled building system having a plurality of interconnected joist assemblies, studs, blocking members and flooring members according to one example embodiment;
FIG. 24 illustrates a section view of a flooring retaining member according to one example embodiment;
FIG. 25 illustrates a perspective view of a perspective view of partially assembled building structure showing an interaction of flooring retaining members 196 with first and second flooring members according to one example embodiment;
FIG. 26 illustrates a second perspective close-up view of a pair of flooring retaining members according to the example embodiment;
FIG. 27a illustrates a first perspective view of a pair of flooring retaining members having formed a mutual interlocking engagement according to one example embodiment;
FIG. 27b illustrates a second perspective view of a pair of flooring retaining members having formed a mutual interlocking engagement according to one example embodiment;
FIG. 28 illustrates a section view along the line B-B of a panel retaining member according to one example embodiment;
FIG. 29 illustrates a section view along the line C-C of an interfacing member for retaining the panel retaining member;
FIG. 30 illustrates a section view of an interaction between two panel retaining members and an interfacing member in a first stage of assembly according to one example embodiment;
FIG. 31 illustrates a section view of an interaction between the two panel retaining members and the interfacing member in a second stage of assembly;
FIG. 32 illustrates a section view of the interaction between two panel retaining members and the interfacing member in a third stage of assembly;
FIG. 33 illustrates a section view of the interaction between two panel retaining members and the interfacing member when assembled together;
FIG. 34 illustrates a section view of a locking apparatus according to one example embodiment;
FIG. 35 illustrates a perspective view of the interaction of an interfacing member with a locking apparatus;
FIG. 36 illustrates the perspective view of FIG. 35 with the locking apparatus shown in transparency.
FIG. 37 illustrates a perspective view of the locking apparatus being fully engaged with an interfacing member according to one example embodiment;
FIG. 38 illustrates the perspective view of FIG. 37 with the interfacing member shown in transparency;
FIG. 39 illustrates a close-up view of the assembly of the interfacing member with the structural subsystem;
FIG. 40 illustrates a close up-view of the assembly of the interfacing members with the structural subsystem with locking plates not being shown;
FIG. 41 illustrates a perspective view of an exemplary assembly of four interfacing members locked using a locking apparatus;
FIG. 42 illustrates a section view of a partially assembled wall-to-ceiling assembly;
FIG. 43 illustrates a perspective of a wall-to-ceiling assembly according to example embodiment;
FIG. 44 illustrates a perspective of the wall-to-ceiling assembly with locking plates removed for better clarity;
FIG. 45 illustrates a rear perspective view of the wall-to-ceiling assembly illustrated in FIG. 43;
FIG. 46 illustrates the rear perspective view of FIG. 45 with locking plates removed for better clarity;
FIG. 47 illustrates a close-up view of a partially assembled building system having at least one modular wall panel according to one example embodiment;
FIG. 48 illustrates a perspective view of a partially assembled building system having a plurality of modular ceiling panels according to one example embodiment;
FIG. 49 illustrates an exploded view of a modular building system according to one example embodiment;
FIG. 50 illustrates a fully assembled modular building system in accordance with an example embodiment;
FIG. 51 illustrates a perspective view of a partially assembled first building system having an irregular shape according to one example embodiment;
FIG. 52 illustrates a perspective view of the first irregularly shaped building system in a fully assembled form;
FIG. 53 illustrates a perspective view of a second partially assembled building system having an irregularly shape according to one example embodiment; and
FIG. 54 illustrates a perspective view of the second partially assembled building system having the irregular shape in a fully assembled form.
DETAILED DESCRIPTION
In the following description, the same numerical references refer to similar elements. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures or described in the present description are embodiments only, given solely for exemplification purposes.
Moreover, although the embodiments of the kit for a modular building system and modular building assembled therefrom and corresponding parts thereof consist of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential and thus should not be taken in their restrictive sense. It is to be understood, as also apparent to a person skilled in the art, that other suitable components and cooperation thereinbetween, as well as other suitable geometrical configurations, may be used for the kit for a modular construction and modular building assembled therefrom, as will be briefly explained herein and as can be easily inferred herefrom by a person skilled in the art. Moreover, it will be appreciated that positional descriptions such as “above”, “below”, “left”, “right” and the like should, unless otherwise indicated, be taken in the context of the figures and should not be considered limiting.
Referring generally to FIGS. 1a and 1b, in accordance with one embodiment, there is provided a joist supporting member 2 of joist assembly 8. FIG. 1b illustrates concealed elements of the joist supporting member in stippled lines. The joist supporting member 2 comprises a pinched portion 12 and an interfacing portion 16 extending from the pinched portion 12. The pinched portion 12 has opposing faces that each engage a respective one of a pair of oppositely facing beam members 20, 24 of the joist assembly 8. FIG. 2 illustrates a rear perspective view of the joist supporting member 2 according to an example embodiment.
Referring now to FIG. 3, therein illustrated is an exploded view of the joist assembly 8 in accordance with an example embodiment. A first beam member 20 of the oppositely facing beam members engages a first surface of the pinched portion 12 and a second beam member 24 is positioned to engage a second surface of the pinched portion 12. Upon assembly, the joist supporting member 2 is partially pinched between the pair of oppositely facing beam members 20, 24. As illustrated, the pinched portion 12 is pinched and the interfacing portion 16 extends from a lower surface 28 of the pair of oppositely facing beam members 20, 24. The joist supporting member 2 may maintain engagement with the oppositely facing beam members 20, 24 using a suitable adhesive or with the use of fasteners, which may project through fastener openings of the pinched portion 12. The fasteners may be suitable screws and/or nuts and bolts that project through the first and second beam members 20, 24. The joist assembly 8 may be included in a kit for a modular building system.
Referring now to FIG. 4, therein illustrated is a perspective view of an assembled joist assembly 8 according to one example embodiment. The pinching of the pinched portion 12 between the oppositely facing beam members 20, 24 causes the oppositely facing beam members to be spaced apart to define a gap 40 therebetween. As illustrated, the gap extends along a lengthwise direction 44 of the joist assembly 8.
The width of the gap 40 corresponds to a thickness of the joist supporting member 2. For example, and as illustrated, the joist supporting member 2 is a plated member.
As described elsewhere, the gap 40 is operable to receive at least one connector for joining the joist assembly 8 with at least one supported member of the kit for a modular building system. The at least one connector generally includes a retaining portion that retains the supported member and a retained portion that is insertable into the gap 40 to engage the joist assembly 8. The supported member is oriented transversely to the pair of oppositely facing beam members 20, 24 when the retained portion is received within the gap 40.
Referring now to FIG. 5, therein illustrated is a perspective view of a partially assembled building system according to a first example embodiment in which the joist assembly 8 is assembled with a joist assembly supporting member 48. For example, as illustrated, the joist assembly supporting member 48 is a stud or post of a building system. Upon assembly, the joist assembly 8 is supported by the joist assembly supporting member 48 via an engagement of the interfacing portion 16 of the joist supporting member 2 with the joist assembly supporting member 48.
According to one example embodiment, the joist assembly supporting member 48 is a supporting stud that has a recess formed in its upper end 52. The joist supporting member 2 further includes a protruding sub-portion 54 that extends from its pinched portion 12. For example, the protruding sub-portion 54 extends transversely relative to a lower surface 28 of the pair of oppositely facing beam members 20, 20 upon the joist supporting member 2 being pinched therebetween. The protruding sub-portion 54 is inserted into the recess of the upper end 52 of the supporting stud 48. This insertion maintains engagement of the joist assembly 8 with the supporting stud 48. It will be appreciated that the protruding sub-portion 54 acts as male engagement member while the recess at the upper end 52 acts as a female receiving member. Upon assembly, the joist assembly 8 is supported upon the supporting stud 48 by the force of gravity.
It will be appreciated that the engagement of the joist assembly 8 with the joist assembly supporting member 48 via the joist supporting member 2 facilitates assembly and disassembly. The assembly of these two building elements may consist of the insertion of the protruding sub-portion 54 into a cooperating recess of the joist assembly supporting member 48. The disassembly may further consist of disengaging the protruding sub-portion 52 from the cooperating recess of the joist assembly supporting member 48.
According to one example embodiment, the engagement of the joist assembly 8 with the joist assembly supporting member 48 is maintained free of (i.e. without) use of any fasteners connecting the joist assembly 8 with the joist assembly supporting member 48.
Referring back FIG. 1, the interfacing portion 16 of the joist supporting member 2 may also include a fastenable portion 56. For example, and as illustrated, the fastenable portion 56 is located between the pinched portion 12 and the protruding sub-portion 54. The interfacing portion 16 may be wider than the protruding sub-portion 54 and has formed therein at least one opening 60.
Referring back to FIG. 5, it will be appreciated that upon assembly, the fastenable portion 56 also extends from the lower surface of the oppositely facing beam members 20, 24. The fastenable portion 56 further has a width that is greater than a width of the supporting member 48 (ex: supporting stud) such that the fastener openings 60 are exposed. The fastener openings 60 are adapted to receive a fastener for connection with one or more supporting members that are one or more bracings 64. In the illustrated example, two bracings 64 are provided and are oriented diagonally to the supporting stud 48.
Referring now to FIG. 6, therein illustrated is a perspective view of a partially assembled modular building system according to one example embodiment that includes upper joist assemblies 8a, lower joist assemblies 8b and studs 48. The studs 48 act as joist assembly supporting members 48 for the upper joist assemblies 8a. As described elsewhere herein, the studs 48 represented supported members relative to the lower joist assemblies 8b and are supported by the lower joist assemblies 8b. As illustrated, the protruding sub-portions 54 of the joist supporting members of the lower joist assemblies 8b can be seen extending from their lower surface for engagement with other supporting members 48.
Referring now to FIG. 7, therein illustrated is a perspective view of the partially assembled modular building system according to an alternative example embodiment that further includes a plurality of bracings 64. The bracings 64 extend diagonally from the upper joist assemblies 8a and are further fastened to the lower joist assemblies 8b or connectors for engagement of the lower joist assemblies 8b with the studs 48.
Referring now to FIG. 8, therein illustrated is a perspective view of a double-ended connector 72 that may be included in a kit for a modular building system for forming a connection between a joist or a joist assembly 8 with a supported member of the kit. The double-ended connector 72 includes a body portion 76, a first leg member 80 extending in a first direction from the body portion 76 and at least one second leg member 84 extending in a second direction from the body portion 76. As illustrated, the first leg member 80 extends in a first direction that is opposite to the second direction in which the at least one second leg member 84 is extending.
The first leg member 80 is engageable with a cooperating supported stud. Within various example embodiments of the kit for a modular building system, the supported stud represents one of the at least one supported member. The cooperating supported stud has a recess formed in a bottom end of the supported stud that is sized to receive the first leg member 80. Upon such engagement, the supported stud is supported upon the body portion 76 of the double-ended connector.
The at least one second leg member 84 is engageable with a joist or a joist assembly 8. For example, the second leg member 84 may be received within a cooperating recess, slot or gap of the joist or joist assembly 8. Upon such engagement with the joist or joist assembly, the connector 72 is supported by the joist or joist assembly 8. Accordingly, upon assembly, the supported stud is supported by the double-ended connector 72 and the connector 72 is further supported by the joist or joist assembly 8.
According to various example embodiments, the double-ended connector 72 corresponds to one of the at least one connector of the kit for a modular building system for forming a connection between the joist assembly 8 described herein according to various example embodiments. The supported stud corresponds to one of the at least one supported member being retained by the double-ended connector 72. The first leg member 80 corresponds to the retaining portion of the double-ended connector 72 that acts to retain the supported stud and the at least one second leg member 84 corresponds to the retained portion of the double-ended connector that engages the joist assembly 8.
More particularly, the at least one second leg member 84 is insertable into the gap 40 of the joist assembly 8 through an upper plane defined by top surfaces 86 of the oppositely facing beam members 20, 24 of the joist assembly 8. This insertion causes the double-ended connector 72 to form an engagement with the joist-assembly 8. The first leg member 80 is further insertable into the recess of the bottom end of the supported stud to form an engagement therewith, whereby the supported stud is supported on the body portion 76.
Referring now to FIGS. 9a and 9b, therein illustrated a perspective view and side elevation view, respectively, of a partial assembly of the double-ended connector 72 with a joist assembly 8 according to an example embodiment. As illustrated, upon assembly, the at least one second leg member 84 is inserted into the gap 40 whereby the body portion 76 and the first leg member 80 are positioned above the top surface 86 of the joist assembly 8. In this position, the double-ended connector 72 is ready to receive the supported stud.
According to one example embodiment, and as illustrated, the body portion 76 of the double-ended connector 72 includes a plated sub-portion 88. The plated sub-portion 88 may be oriented substantially perpendicularly to the first leg member 80 and the at least one second leg member 84. Upon assembly of the double-ended connector 72 to the joist assembly 8, the plated sub-portion 88 is oriented substantially parallel to the top surfaces 86 of the oppositely facing beam members 20, 24. The plate sub-portion 88 is adapted to support the bottom end of the supported stud.
According to one example embodiment, and as illustrated, the plated sub-portion 88 is spaced apart from the at least one second leg member 84. Furthermore, upon assembly, the plated sub-portion 88 is positioned so as to be spaced apart from the top surface 86 of the joist assembly 8. As a result, the supported stud will also be spaced apart from the top surface 86 of the joist assembly 8. For example, the body portion 76 comprises transverse walls 92 that extend from an underside of the plated sub-portion 88. Upon assembly, the transverse walls 92 abut the top surface 86 of the joist assembly 8 to maintain the spacing of the plated sub-portion 88 from the joist assembly 8. The portion of the body portion corresponding to the spacing between the plated sub-portion 88 and the joist assembly 8 represents an interfacing portion of the double-ended connector 72.
The interfacing portion of the double-ended connector 72 may be used to guide the placement of one or more flooring members over the joist assembly 8. The flooring member may include sub-flooring elements. For example, a portion of the flooring members may be located within the space between plated sub-portion 88 and the top surface of the joist assembly 8. Corners of the flooring members may abut against the transverse walls 92 so as to maintain proper placement of the flooring members.
For example, and as illustrated, the interfacing portion of the body portion 76 of the double-ended connector 72 may further define one or more fastener openings 96 for connection with a bracing.
Referring back to FIG. 2, according to one example embodiment, one of the surfaces of the pinched portion 12 of the joist supporting member 2 includes a recessed surface 98. The recessed surface 98 forms an additional gap with an inner surface of the one of the oppositely facing beam members 20, 24. The additional gap is adapted to receive the at least one second leg member 84 of the double-ended connector 72. The second leg member 84 may be partially supported by the joist supporting member 2 within the additional gap.
Referring now to FIG. 10, therein illustrated a perspective view of a partially assembled modular building system showing an intermediate step of assembling a supported stud 48 to a joist assembly 8. As illustrated, a bottom end 104 of the supported stud 48 has a recess 108 that extends to an edge of the bottom end 104. An upper joist assembly member 8a is first connected to an upper end of the supported stud 48. The first leg member 80 of a double-ended connector 72 is then inserted into an open side of the recess 108. The first leg member 80 may be inserted into the recess 108 while the supported stud 48 may be lied flat. The supported stud 48 is then pivoted to an upright position over the double-ended connector 72.
Referring back to FIGS. 6 and 7, the supported stud 48 is supported over the lower joist assembly 8b. Upon assembly, the supported stud is supported by the double-ended connector 72 and the double-ended connector 72 is further supported over the lower joist assembly 8b. As illustrated, the bottom end of the supported is spaced apart from the lower joist assembly 8b.
Referring now to FIG. 11, therein illustrated is a perspective view of a hanger connector 120 that may be included in a kit for a modular building system for forming a connection between a joist or a joist assembly 8 with a supported member. The hanger connector 120 includes a retaining portion 124 engageable to an end of a blocking member. The hanger connector 120 further includes a retained portion 128 engageable with the joist or joist assembly 8. According to various example embodiments of the kit for a modular building system, the blocking member represents one of the at least one supported member.
The retaining portion 124 can be attached to an end of the blocking member according to various attachment methods known in the art. For example, and as illustrated, the retaining portion 124 has a I-shaped cross section formed of a top wall 132, a bottom wall 136 and an upstanding wall 140 that can be attached to the end of the blocking member, for example, by, friction fit, press fit, or using suitable adhesives. According to one example embodiment, to further strengthen the attachment of the retaining portion 124 of the hanger connector 120 to the end of the blocking member, one or more fasteners may project through openings in top and bottom walls 132, 136 and vertically through an end of the blocking member.
According to one example embodiment, the retained portion 128 includes a supported sub-portion 144 extending longitudinally from the retaining portion 124 and at least one leg sub-portion 148 extending downwardly from a distal end of the supported sub-portion 144. The retained portion 128 has a hook-like interaction with a joist or beam member 20, 24 of a joist assembly 8 to form an engagement therewith.
According to the example illustrated in FIG. 11, a pair of hanger connectors 120 are provided and positioned oppositely one another. The hanger connectors 120 are each connected to a respective blocking member and cooperate with one another when engaged to a joist or joist assembly. For example, each hanger connector 120 has a plurality of leg sub-portions that are staggered relative to one another upon engagement onto a joist or joist assembly.
A strengthening plate 152 may be provided to further strengthen the cooperating engagement of the pair of hangar connectors 120.
Referring now to FIG. 12, therein illustrated is an exemplary engagement of the cooperating hanger connectors 120 and the strengthening plate 152 with the joist and blocking members being absent. The strengthening plate 152 is oriented substantially parallel to the surface of the supporting sub portions 144 of the hanger connectors 120. A transverse slot 153 is further formed within the strengthening plate 152. The leg sub-portions 148 of the hanger connectors 120 project through the transverse slot 153 and are engaged to the strengthening plate 152 by a hooking action. It will be appreciated that the leg sub-portions 148 are oriented substantially perpendicularly to a surface of the strengthening plate 152 when received within the transverse slot 153.
According to an alternative example embodiment, the strengthening plate 152 is oriented perpendicularly to the surfaces of the supporting sub-portions 144. The leg sub-portions 148 of each hanger connector 120 is located on an opposite side of the strengthening plate 152, whereby the plate 152 restricts separation of the cooperating hanger connectors 120 from one another when pulled away from one another. Accordingly, the strengthening plate 152 is pinched between inner surfaces of the leg sub-portions 148 of the hanger connectors 120. According to alternative example embodiment, the leg sub-portions 148 are oriented parallel to the surface of the strengthening plate 152.
Referring now to FIGS. 13 and 14 simultaneously, therein illustrated is a perspective view of a partially assembled modular building system according to one example embodiment that includes a joist assembly 8 and first and second blocking members 156a, 156b. FIG. 14 shows concealed elements in stippled lines. The blocking member 156a, 156b represent support members relative to the joist assembly 8 and is connected thereto via their respective hangar connectors 120.
The leg sub-portions 148 of each hangar connectors 120 are insertable into the gap 40 of the joist assembly 8. For a first of the hangar connectors 120, upon assembly, its leg sub-portions 148 are received with the gap 40. The supported sub-portion 144 of the retained portion 128 is disposed and supported on an upper surface 86 of the first beam members 20 of the joist assembly 8. An inner surface 166 of the leg sub-portion 148 frictionally engages an inner sidewall of the first beam member 20. An end 164 of the first blocking member 156a abuts an outer sidewall 168. Accordingly, the first blocking member 156a is supported by the first blocking member 156a of the joist assembly 8 via a hanging interaction with the first beam member 20.
The second blocking member 156b is engaged to the joist assembly 8 in a similar manner as the engagement of the first blocking member 156a as described above.
As illustrated, when supported by the joist assembly 8, the first and second blocking members 156a, 156b are oriented transversely to the lengthwise direction of the joist assembly 8 and within a same horizontal plane of the joist assembly 8.
According to various example embodiments, the upper surface 160 of the first beam member 156a includes at least one recessed portion 172 (ex: as seen in FIG. 4). For example, the first beam member 156a has a plurality of equally spaced recessed portions 172. Upon assembly, the supported sub-portion 144 of the hanger connector 120 is received within the recessed portion 172. When so received, the top surface of the supported sub-portion is substantially co-planar with the upper surface 160 of the first beam member 156a. Accordingly, the top surface of the supported sub-portion 144 and the upper surface 86 of the joist assembly 8 form a substantially smooth surface, which may be used to support flooring members of the modular building system.
According to various example embodiments, and as illustrated, upon assembly, a blocking member 156a, 156b is positioned on each side of the joist assembly 8 and opposite one another such that they are aligned along an axis transverse to the lengthwise direction of the joist assembly 8. The first blocking member 156a is received within the gap 40 within a recessed portion 172a at a given position along the length of the joist assembly 8 and abuts the lateral sidewall 160 of the first beam member 20. Similarly, the second blocking member 156b is received within the gap 40 and within a recessed portion 172b at the same given position along the length of the joist assembly 8. It will be appreciated that the blocking members 156a, 156b act as building elements that provide support transversely to the joist assembly 8 within an assembled modular building system.
Referring now to FIGS. 15 and 16, therein illustrated is a perspective view of an interaction of a joist supporting member 2, first and second hanger connectors 120a, 120b and a double-ended connector 72 according to one example embodiment. FIG. 16 shows concealed elements in stippled lines. It will be appreciated that, upon assembly, the joist supporting member 2, the first and second hanger connectors 120a, 120b and double-ended connector 72 occupy substantially the same space.
The at least one second leg member 84 of the double-ended connector 72 according to the example illustrated in FIGS. 15 and 16 includes a pair of leg members 84 spaced apart relative to one another to define an additional gap 176 between the leg members 84. The leg members 84 are received with the recessed portion 98 in the pinched portion 12 of the joist supporting member 2. The hanger connectors 120a, 120b are partially located within the additional gap 176. As illustrated, the supported sub-portions 144 of the hanger connectors 120a, 120b are located within the additional gap 176. The doubled-ended connector 72 may be further supported over the top surface of the supported sub-portion 144.
Referring now to FIGS. 17a and 17b, therein illustrated is a perspective view of a partially assembled building system having a joist assembly 8 supporting a first supported member being a supported stud 100 and second supported members being a pair of blocking members 156a, 156b. The first hanger connector 120a is received within the gap 40 of the joist assembly 8 to retain the first blocking member 156a at a given position along the length of the joist assembly 8. The second hanger connector 120b is also received within the gap 40 of the joist assembly 8 to retain the second blocking member 156b to the joist assembly 8 at the same position along the length of the joist assembly 8. The doubled ended connector 72 is also received within the gap 40 at the same given position along the length of the joist assembly 8 and supports the supported stud 100. It will be appreciated that upon assembly, the joist assembly 8, the first and second blocking members 156a, 156b and the supported stud 100 define three mutually perpendicular axes of the modular building system.
Referring now to FIG. 18, therein illustrated is a perspective view of a partially assembled modular building system having a plurality of interconnected joist assemblies 8, studs 100 and blocking members 156 according to one example embodiment. The partially assembled building system illustrated in FIG. 18 represents a structural subsystem of the building system. The structural subsystem refers to those assembled elements of the building system that are adapted to bear a load and that are further adapted to retain modular wall panels and/or modular ceiling panels. The example embodiments lower joist assemblies 8 being assembled with a plurality of transversely oriented lower blocking members 156. The studs 100 are supported by the lower joist assemblies 8 and further support the upper joist assemblies 8, which are further assembled with a plurality of transversely oriented upper blocking members 156.
Referring now to FIGS. 19 and 20, therein illustrated is a perspective view of a partially assembled modular building system having a joist assembly 8 supporting the supported stud 100, the second supported members 156a, 156b and further a plurality of first flooring members 180. According to the illustrated example, the supported stud 100 is spaced apart from the upper surface 160 of the joist assembly 8 and the upper surface 184 of the blocking members 156a, 156b. As further illustrated, the corners of the flooring elements 180 are located within the space between the bottom end 104 of the supported stud 100 and the upper surface 184 and further abut against transverse walls 92 of the body portion 76 of the double-ended connector 72. The first flooring members 180 may form a sub-flooring of the building system.
Referring now to FIGS. 21 and 22, therein illustrated are perspective views of a partially assembled building system having top flooring members supported over the sub-flooring. A plurality of floor supporting members 188 are positioned over the sub-flooring formed by the first flooring members 180. The plurality of floor supporting members 188 include a plurality of upstanding members and a plurality of diagonally oriented truss supporting members. The plurality of floor supporting members 188 support the top flooring, which may be formed by a plurality of second flooring members 192. For example, the top surface of the second flooring members 192 have an aesthetically pleasing appearance to accommodate occupants of the building system.
The partially assembled building system may include floor retaining members 196 that provide a first interface between the first flooring members 180 and the floor supporting members 180. The first floor retaining members 196 is adapted to engage edges of the first flooring members 188 and to further retain the floor supporting members 188.
The partially assembled building system may further include floor retaining members 196 that provide a second interface between the floor supporting members 180 and the second flooring members 192. The flooring retaining members 196 engage the top ends of the floor supporting members 180 and further retain the second flooring members 192.
Referring now to FIG. 23, therein illustrated is a perspective view of a partially assembled building system having a plurality of interconnected joist assemblies 8, studs 100 and blocking members 156 operating in combination to support a plurality of first flooring members 180.
Referring now to FIG. 24, therein illustrated is a section view along the line A-A (FIG. 25) of a flooring retaining member 196 according to one example embodiment. The flooring retaining member 196 includes a planar body 200. An upstanding connector 204 extends upwardly from a top surface 202 of the planar body 200. The upstanding connector 204 includes a central wall 208 and top wall 212. The top surface 202 of the planar body 200, the central wall 208 and the top wall 212 define together at least one upper groove 216. The upper groove 216 is operable to engage an edge of a flooring member of the modular building system, such as the first flooring member 180 and/or second flooring member 192. For example, the flooring member is retained by the flooring retaining member 196 by frictional engagement with surface of the planar body 200, the central wall 208 and the top wall 212.
The flooring retaining member 196 further includes a pair of central walls 220 extending from a bottom surface 224 of the planar body 200, which define together a second groove 228. The second groove 228 is operable to engage an end of an upstanding flooring supporting member 188.
According to one exemplary embodiment, the flooring retaining member 196 is operably to be used in two orientations (right side up, as illustrated, and upside down) to retain first flooring members 180 or second flooring members 192.
In the right side up orientation, as illustrated in FIG. 24, the flooring retaining member 196 is operable to retain the second flooring members 192 while being supported above a plurality of the flooring supporting members 188. Top ends of uprightly oriented flooring supporting members 188 are received within the second groove 228, whereby the flooring retaining member 196 is supported by the flooring supporting members 188. The second flooring members 192 are further received within the first groove 216, whereby the second flooring members 192 are supported over the top surface 202 of the planar body 200.
In the upside down orientation, the flooring retaining member 196 is operable to retain the flooring supporting members 188 while supporting the first flooring members 192. The edge of the first flooring member 192 is received with the first grove 216, whereby the flooring retaining member 196 is supported over an upper surface of the first flooring member 192. A bottom end of the flooring supporting member 188 is received within the second groove 228, whereby the flooring supporting member 188 is supported over the bottom surface 224 of the flooring retaining member 196.
Referring now to FIG. 25, therein illustrated is a first close-up perspective view of a pair of flooring retaining member 196
Referring now to FIG. 26, therein illustrated is a second close-up perspective view of the pair of flooring retaining members 196. It will be appreciated that a first end 232 of a first of the flooring retaining members 196 and a second end 236 of the other of the flooring retaining members 196 is shown. The first end 232 has formed in at least one lateral edge thereof at least one first cutaway portion 240. In the illustrated example, a cutaway portion 240 is formed in each lateral edge of the first end 232.
The second end 236 has formed in an end edge thereof at least one second cutaway portion 244. In the illustrated example, a second cutaway portion 244 is formed in proximity of each lateral edge of the second end 236.
The first cutaway portion 240 and the second cutaway portion 244 are sized and shaped to form interlocking engagement with one another to join together the pair of flooring retaining members 196.
Referring now to FIG. 27a, therein illustrated is a first close-up perspective view of the pair of flooring retaining members 196 having formed the mutual interlocking engagement. A first end corner 248 of the first end 232 is received within the second cutaway portion 244 while a second end corner 252 of the second end 236 is received within the first cutaway portion 240.
FIG. 27b illustrates a second close-up perspective of the pair of flooring retaining member 196 having formed the mutual interlocking engagement.
Referring now to FIG. 28, therein illustrated is a section view along the line B-B of a panel retaining member 260 according to one example embodiment. The panel retaining member 260 corresponds to an element of a modular wall panel of a kit for forming a modular building system. The panel retaining member 260 includes a first sidewall 264, a second sidewall 268 and a bottom wall 272. The first and second sidewalls 264, 268 extend upwardly from a top surface 276 of the bottom wall 272 and are positioned oppositely one another. The first sidewall 264, the second sidewall 268 and the bottom wall 272 define together a slot 280 in which may be received one or more insulating elements of the modular wall panel. The insulating elements may include an insulating panel, which may be received within the slot 280.
According to one example embodiment, surfaces of the insulating panel member frictionally engage surfaces of the first sidewall 264, second sidewall 268 and bottom wall 272 to be retained within or over the slot 280. The insulating panel member is oriented perpendicularly to the bottom wall 272.
Alternatively, a panel supporting member of the insulating elements may be received within the slot 280 and one or more insulating panels may be supported over top surface of the panel supporting members and a top surface 273 of the first sidewalls 264.
Accordingly, the insulating panel is retained via the slot 280 of the panel retaining member.
The first side wall 264, second sidewall 268 or both may have formed therein threaded openings 284, 288 to receive cooperating threaded fasteners that further contribute to retaining the insulating elements within the slot 280. The threaded fastener may be used to fasten the panel retaining member 260 with another panel retaining member that is oriented perpendicular to it within the modular wall panel. The second sidewall 268 may have further formed therein a second opening 292 for receiving a flexible sealing member.
Continuing with FIG. 28, the panel retaining member 260 further includes a pair of gripping strips 300 extending outwardly from an outer surface 296 of the first sidewall 264. The gripping strips 300 define together a groove 304. The groove 304 is operable to receive therein a cooperating tongue member of a thermal bridge breaking member as described elsewhere herein.
Referring now to FIG. 29, therein illustrated is a section view along the line C-C of an interfacing member 320 for retaining the panel retaining member 260 and for forming a connection with flooring elements of a modular building structure. The interfacing member 320 includes a body 324 having a frontal wall 328 and a rearward wall 332. A plurality of locking strips extend forwardly from the frontal wall 328 to define at least one forward slot for receiving the second sidewall 268 of the panel retaining member 260.
In the example illustrated in FIG. 29, the example interfacing member 320 includes an upper locking strip 336, a lower locking strip 340, an upper central locking strip 344 and a lower central locking strip 348. The upper locking strip 336 extends forwardly from an upper edge of the frontal wall 328. The lower locking strip 340 extends forwardly from a lower edge of the frontal wall 328. The upper central locking strip 344 extends forwardly from a central portion of the frontal wall 328. The lower central locking strip 348 also extends forwardly from a central portion of the frontal wall 328. The upper locking strip 336, the upper central locking strip 344 and an upper portion of the frontal wall 328 define together an upper forward slot 352 for receiving a panel retaining member. The lower locking strip 340, the lower central locking strip 348 and the lower portion of the frontal wall 328 define together a lower forward slot 356 for receiving another panel retaining member.
The rearward wall 332 has defined therein at least one rearward slot for engaging an external connector. For example, the external connector may be a connector that connects to the structural subsystem of the modular building structure. In the example illustrated in FIG. 29, the rearward wall 332 of the interfacing member 320 includes an upper rearward slot 360 and a lower rearward slot 364.
Referring now to FIG. 30, therein illustrated is a section view of an interaction of two panel retaining members 260a, 260b with the interfacing portion 320. In the illustrated example, the lower panel retaining member 260b has already been assembled with the interfacing portion 320 via the engagement of the second sidewall 268b within the lower forward slot 356. As illustrated, upon assembly, the lower locking strip 340 engages an outer surface of the second sidewall 268b and the lower central locking strip 348 engages an outer surface of the bottom wall 272b of the lower panel retaining member 260b.
Continuing with FIG. 30, the upper panel retaining member 260a is in an initial stage of assembly with the interfacing member 320. The second sidewall 268a is aligned with the upper forward slot 352 of the interfacing portion 320. Surfaces 368 of the second sidewall 268a represent surfaces that form a frictional engagement with surfaces of the interfacing member 320.
According to one example embodiment, and as illustrated in FIG. 30, the upper central locking strip 344 includes a first groove 372. The outer surface of the bottom wall 272a of the upper panel retaining member 260a also includes a tongue 380a that cooperates with the first groove 372. Similarly, the lower central locking strip 348 includes a second groove 376. The outer surface of the bottom wall 272b of the lower panel retaining member 260b also includes a tongue 380b that cooperates with the second groove 376. As illustrated, the tongue 380b is received within the second groove 376 to further strengthen the engagement of the lower panel retaining member 260b within the lower forward slot 356 of the interfacing member 320. According to various example embodiments, the upper central locking strip 344 and the lower central locking strip 348 are resilient members that are biased away from one another. In the illustrated example, the lower central locking strip 348 is biased towards the tongue 380b to further increase their mutual engagement. The resiliency causes the second sidewall 268b of the lower panel retaining member 260 to be pinched between the lower central locking strip 348 and the lower locking strip 340.
Referring now to FIG. 31, therein illustrated is a section view of an interaction of the two panel retaining members 260a, 260b with the interfacing member 320 in which the panel retaining member 260a is in a second stage of assembly with the interfacing member 320. An end of the upper central locking strip 344 is contacting a forward edge of the tongue 380a as the upper panel retaining member 260a is advanced towards the interfacing member 320.
Referring now to FIG. 32, therein illustrated is a section view of the interaction of the two panel retaining members 260a, 260b with the interfacing member 320 in which the panel retaining member 260a is in a third stage of assembly with the interfacing member 320. A widest portion of the tongue 380a abuts the widest portion of the upper central locking strip 344, thereby flexing the resilient upper central locking strip 344 towards the lower central locking strip 348.
Referring now to FIG. 33, therein illustrated is a section view of the interaction of the two panel retaining members 260a, 260b with the interfacing member 320 in which the panel retaining members 260a, 260b have been fully assembled with the interfacing portion 320. It will be appreciated that the tongue 380a of the upper panel retaining member 260a is received within the groove 372 of the upper central locking strip 344. Furthermore, the second sidewall 268 of the upper retaining member 260a is received within the upper forward slot 352 of the interfacing portion 320, wherein the contacting surfaces 368 frictionally engage surfaces of the upper frontal wall 328, upper locking strip 336 and the upper central locking strip 344.
Referring now to FIG. 34, therein illustrated is a section view of a locking apparatus 400 for engaging the interfacing member 320 according to one example embodiment. The engagement of the locking apparatus 400 with the interfacing member 320 further promotes the engagement of the interfacing member 320 with the panel retaining members 260. The locking apparatus 400 includes a central body 404 and a plurality of locking members 408 extending therefrom. In the illustrated example, the locking apparatus 400 includes four locking members 408 extending in four directions along two mutually perpendicular axis. The central body 404 may define a central opening 412 for receiving a cooperating male post member for engaging the locking apparatus 400.
Referring now to FIGS. 35 and 36, therein illustrated is a perspective view showing the interaction of an interfacing member 320, with a locking apparatus 400 and further with a locking plate 420. For clarity of illustrate, panel retaining members 320 that may be received within the forward slots 352, 360 are not shown. FIG. 36 shows the locking apparatus 400 in transparency. The locking plate 420 is placed against an extended portion 424 of the rearward wall 332 of interfacing member 320. The extended portion 424 corresponds to an end portion of the interfacing member 320 in which elements extending from the rearward wall 332 are absent so as to accommodate the locking pate 424. As illustrated, the extended portion 424 has tapered edges 428 that extend from outer edges of the interfacing member 320.
Continuing with FIGS. 35 and 36 a central male post member 432 extends from a forward surface of the locking apparatus 400. The central male post member 432 may be externally threaded. The central male post member 432 extends through the central opening 412 of the locking apparatus 400. A locking member 408 of the locking apparatus 400 is aligned with a gap 436 defined between the upper central locking strip 344 and lower central locking strip 348. The locking member 408 is inserted into the gap 436. The locking member 408 is sized to engage the upper central locking strip and the lower central locking strip 348 to push these strips away from one another. The interfacing member 320 may further include a central peg 440 that projects into an opening 444 of a locking member 408 to guide alignment of the locking member 408 within the gap 436. A nut member 448 is fastened to the central male post member 432 and retains the locking apparatus 400 against the interfacing member 320.
Referring now to FIGS. 37a and 37b, therein illustrated is a perspective view showing the locking apparatus 400 being fully engaged with an interfacing member 320. FIG. 37b shows the interfacing member in transparency. It will be appreciated that the locking apparatus 400 is retained through further fastening of the nut member 448. The first locking member 408 is further received within the gap 436. It will appreciated that when panel retaining members 260 are received within the upper forward slot 352 and lower rearward slot 356, the biasing of the upper and lower central locking strips 344, 348 away from one another due to the locking member 408 further promotes engagement of the panel retaining members 260 with the interfacing member 320.
It will be appreciated that the locking apparatus 400 may be used to simultaneously engage four interfacing members 320, thereby promoting the retaining of four modular wall panels (one panel between each pair of adjacent interfacing member 320).
As described elsewhere herein, the rearward wall 332 of the interfacing member 320 has defined therein at least one rearward slot for engaging an external connector. Referring back to FIG. 29, the rearward wall 332 has defined therein an upper rearward slot 360 and a lower rearward slot 364.
According to one example embodiment, at least one of the upper rearward slot 360 or lower rearward slot 364 is sized and shaped to receive therein a connecting edge 460 of the flooring retaining member 196. As illustrated in FIG. 24, the edges of the flooring retaining member 196 have downwardly extending sidewalls that form the connecting edges 460. These sidewalls may further have inwardly facing clipping members 464.
Referring now to FIG. 38, therein illustrated is a perspective view of a partially assembled modular building structure in which modular building panels 472 are engaged with the structural subsystem. This engagement is provided from locking of the interfacing member 320 with a flooring retaining member 196.
Referring now to FIG. 39, therein illustrated is a close-up view of the assembly of the interfacing member 320 with the structural subsystem. The connecting edge 460 of the flooring retaining member 196 is received within the upper rearward slot 452 of the interfacing member 320. The inwardly facing clipping members 464 engage an inner lip 482 of the upper rearward slot 452 to provide a locking of the connecting edge 460 within the upper rearward slot 452. As illustrated, the locking plate 420 engages the locking apparatus 400, which further retains three interfacing members 320.
Referring now to FIG. 40, therein illustrated is a close-up view of the assembly of the structural subsystem with a plurality of interfacing members 320. For clarity of illustrates, the locking plate 420 and flooring member 192 are not shown. It will be appreciated that three interfacing members 320 are placed together, whereby their tapered edges 428 abut one another and join at the central body 404 of the locking apparatus 400. A leftmost one of the interfacing members 320 is engaging a connecting edge 460 of the flooring retaining member 196. It will be understood that insulating panel members retained via the panel retaining members 260 received within the interfacing members 320 are oriented perpendicularly to the body portion 200 of the floor retaining member 196.
FIG. 41 illustrates a perspective view of an exemplary assembly in which four interfacing member 320a, 320b, 320c, 320d are locked in place using a locking apparatus 400. The locking apparatus 400 is retained in place by nut member 448 fastened over central male post member 432. A first locking member 408a is received within the gap 436a of the first interfacing member 320a, a second locking member 408b is received within the gap 436b of the second interfacing member 320b, a third locking member 308c is received within the gap 436c of the third interfacing member 320c and a fourth locking member 308d is received within the gap 436d of the fourth interfacing member 320d.
Referring now to FIG. 42, therein illustrated is a section view of a partially assembled wall-to-ceiling assembly 470 having a modular wall panel 472 being connected to a modular ceiling panel 480.
A first panel retaining member 260a, a second panel retaining member 260b and a first thermal bridge breaking member 488a define together a first sub-panel element of the modular wall panel 472. As illustrated, a first tongue member 492a of the thermal bridge breaking member 488a extends from a first side of an insulating body 490a thereof and is inserted into the groove 304a defined by first gripping strips 300 of the first panel retaining member 260a. A second panel retaining member 260b is oriented oppositely of the first panel retaining member 260a whereby its first sidewall 264b is facing the first sidewall 264a of the first panel retaining member 260a. A second tongue member 496 extends from a second side of the insulating body 490 is inserted within the groove 304b defined by the second gripping strips 300b of the second panel retaining member 260b.
It will be appreciated that the first panel retaining member 260a, the second panel retaining member 260b and the first thermal bridge breaking member 488 form a first contiguous member. The thermal bridge breaking member 488a is formed of a thermally insulating material. When engaged between the first panel retaining member 260a and the second panel retaining member 260b, the first thermal bridge breaking member 488 provides a break in the thermal path between the first panel retaining member 260a and the second panel retaining member 260b.
A first insulating panel may be retained via the slot 280a of the first panel retaining member 260a and a second insulating panel may be retained via the slot 280b of the second panel retaining member 260b.
According to one example embodiment, and as illustrated, the first panel retaining member 260a and the second panel retaining member 260b are identical.
It will be understood that the length of the thermal bridge breaking member 488 (i.e. the distance between first and second tongue members of the thermal bridge breaking member) may be different according to various example embodiments. The length of the thermal bridge breaking member 488 may depend on the thickness of the modular wall panel being formed. For example, the thickness of the modular wall panel may be varied depending on the thickness of the insulating panels to be used within the modular wall panel.
A third retaining member 260c, a fourth retaining member 260d and a second thermal bridge breaking member 488b are also provided. The third panel retaining member 260c includes a first sidewall 264c, a second sidewall 268c and a bottom wall 272c that define together a slot 280c thereof. One or more third insulating elements may be received within the slot 280c. As illustrated, the third retaining member 260c is oriented in an upside down direction relative to the first panel retaining member 260a. Accordingly, an insulating panel member of the third insulating elements retained via the slot 280c is oriented downwardly.
The fourth panel retaining member 260d includes a first sidewall 264d, a second sidewall 268d and a bottom wall 272d that define together a fourth slot 280d. One or more fourth insulating elements may be received within the slot 280d. As illustrated, the fourth retaining member 280d is oriented in an upside down direction relative to the second panel retaining member 260d. Accordingly, an insulating panel member of the fourth insulating elements retained via the slot 280d is oriented downwardly.
The third panel retaining member 260c, the fourth panel retaining member 260d and a second thermal bridge breaking member 488b form together a second contiguous element of the modular wall panel 472. As illustrated, a first tongue member 492a of the second thermal bridge breaking member 488a extends from a first side of an insulating body 490b thereof and is inserted into the groove 304c defined by first gripping strips 300c of the third panel retaining member 260c. The fourth panel retaining member 260d is oriented oppositely of the third panel retaining member 260c whereby its first sidewall 264d is facing the first sidewall 264c of the third panel retaining member 260c. A second tongue member 496b of the second thermal bridge breaking member 488b extends from a second side of the insulating body 490b thereof and is inserted within the groove 304d defined by second gripping strips 300d of the fourth panel retaining member 260d.
It will be appreciated that the third panel retaining member 260c, the fourth panel retaining member 260d and the second thermal bridge breaking member 488b form a second contiguous member. The thermal bridge breaking member is formed of a thermally insulating material. When engaged between the third panel retaining member 260c and the fourth panel retaining member 260d, the second thermal bridge breaking member 488 provides a break in the thermal path between the third panel retaining member 260c and the fourth panel retaining member 260d.
A third insulating panel may be received within the slot 280c of the third panel retaining member 260c and a fourth insulating panel may be received within the slot 280d of the fourth panel retaining member 260d. Upon assembly, the third and fourth insulating panels extend downwardly relative to the bottom walls 272c and 272d of the third and fourth insulating panels 260c, 260d, respectively.
According to one example embodiment, the first panel retaining member 260a, the second panel retaining member 260b, the third panel retaining member 260c and the fourth panel retaining member 260d are identical.
According to one example embodiment, the first thermal bridge breaking member 488a and the second thermal bridge breaking member 488b are identical.
Continuing with FIG. 42, the first panel retaining member 260a is received within an upper forward slot 352 of the first interfacing member 320a and the third panel retaining member 260c is received within the lower forward slot 356 of the first interfacing member 320a. The upper central locking strip 344a and lower central locking strip 348 are pinched between the bottom wall 272a of the first panel retaining member 260a and the bottom wall 272b of the second panel retaining member 260b.
As illustrated, the first contiguous member formed of the first panel retaining member 260a, the second panel retaining member 260b and the first thermal bridge breaking member 490a is oriented substantially parallel with the second contiguous member formed of the third panel retaining member 260c, the fourth panel retaining member 260d and the second thermal bridge breaking member 490b. A second interfacing member 320b may be provided and engages the second panel retaining member 260b and the fourth panel retaining member 260d. As illustrated, the first sidewall 264c of the third retaining member 260c is received within the upper forward slot 352b of the second interfacing member 320b and the first sidewall 264d of the fourth retaining member 260d is received within the lower forward slot 356b of the second interfacing member 320b.
Upon assembly with the modular ceiling panel 480, a connector provides the interface between the modular wall panel 472 and the modular ceiling panel 480. In the example illustrated in FIG. 43, the connector is provided in the form of a flooring retaining member 196. A connecting edge 460 of the flooring retaining member 196 is received within the upper rearward slot 352 formed in the rearward wall 332a of the first interfacing member 320a. Accordingly, the first interfacing panel 320a is retained by the flooring retaining member 196.
The flooring retaining member 196 engages a third interfacing member 320c, which further engages panel retaining members 260e, 260g of the modular ceiling panel 480. As illustrated, the upstanding connector 204 of the flooring retaining member 196 engages and supports the third interfacing member 320c.
Referring back to FIG. 29, the at least one rearward slot of the exemplary interfacing member 320 further includes a central slot 500 located centrally of the rearward wall 332 between the upper rearward slot 452 and the lower rearward slot 456. An upper rearward edge of the interfacing member 320 has formed thereon a tongue member 504. A lower rearward edge of the interfacing member 320 has formed therein a groove 508.
Referring back to FIG. 30, the upstanding connector 204 is received within the central slot 500c of the third interfacing member 320c. The interfacing member 320c is oriented perpendicularly to the first interfacing member 320a when supported by the flooring retaining member 196. An upper rearward edge of the first interfacing member 320a abuts a lower rearward edge of the third interfacing member 320c. As illustrated, the tongue 504a of the first interfacing member 320a is received within the groove 508c of the third interfacing member 320c, which strengthens the engagement between the first and third interfacing members 320c.
The modular ceiling panel 480 also includes a plurality of insulating elements that further include one or more insulating panel members. For example, the modular ceiling panel 480 has substantially the same elements as the modular wall panel 472. As illustrated, the ceiling panel 480 also includes four panel retaining members 260e, 260f, 260g, 260h and two thermal bridge breaking members 480c, 480d.
Referring now to FIG. 43, therein illustrated is a perspective view of the wall-to-ceiling assembly 470. FIG. 44 shows a plurality of locking members 408 and locking plates 420 that engage the interfacing members 320a, 320b, and 320c. The locking members 408 and the locking plates 420 provide connection with other modular wall panels 472 and/or other modular ceiling panels 480 (now shown).
FIG. 44 illustrates a perspective view of the wall-to-ceiling assembly 470 with the locking plates 420 being removed for better clarity.
FIG. 45 illustrates a rear perspective view of the wall-to-ceiling assembly 470 illustrated in FIG. 43.
FIG. 46 illustrates a rear perspective view of the wall-to-ceiling assembly 470 with the locking plates 420 being removed for better clarity.
FIG. 47 illustrates a close-up view of a partially assembled building structure in which at least one modular wall panel 472 is engaged to supporting structures, such as the joist assembly, studs, and/or flooring members.
FIG. 48 illustrates a perspective view of a partially assembled building structure showing modular ceiling panels 480 placed over uppermost joist assemblies and blocking members.
FIG. 49 illustrates an exploded view of the structural system, modular wall panels 472 and modular ceiling panels 480.
FIG. 50 illustrates a fully assembled modular building structure in accordance with an example embodiment.
FIG. 51 illustrates a perspective view of partially assembled building system having an irregular shape showing its supporting structures.
FIG. 52 illustrates a perspective view of the irregularly shaped building system in a fully assembled form.
FIG. 53 illustrates a perspective view of a second partially assembled building structure having an irregular shape and showing its structural subsystem including flooring members.
FIG. 54 illustrates a perspective view of the second building structure having the irregular shape in a fully assembled form.
It will be understood that various example embodiments of kits described herein may further include various fastening elements known in the art, such as nuts, bolts, screws, and/or nails.
Various elements described herein may be formed of materials generally known in the art of construction systems, such as appropriate metals and woods. For example, connecting elements such as the flooring retaining member 196, panel retaining member 260, and interfacing member may be formed of aluminum for light weight and flexibility during manufacturing. Other elements may be formed of aluminum, steel or other suitable metals. Other suitable materials may be used without straying from the scope of examples embodiments described herein.
Advantageously, various example embodiments described provide increased ease of assembly, disassembly, and/or reconfiguration. For example, such assembly, disassembly and/or reconfiguration may be carried out with the use of mechanized tools. Fore example, the joist assembly 8 is configured so that it can easily interface with double-ended connector 72 and/or hanger connectors 120. The use of such connectors 72, 120 further allow easily connecting the joist assembly 8 with a supported member, such as supported stud 48 and/or blocking member 156. Example embodiments of the floor retaining members 196 further provide an easy to use system interface between the joist assembly 8, supported stud 48 and/or blocking member 120 with first and second flooring members 180, 192. Furthermore, example embodiments of panel retaining members 260, interfacing members 320 and/or flooring retaining members 196 provide an easy to use system for forming modular wall panels and modular ceiling panels, for interconnecting modular wall panels and modular ceiling panels and for connecting modular wall panels and modular ceiling panels to elements of the structure subsystems that include the joist assembly, supported stud 48 and/or blocking members 120. The ease of use applies to assembly of the elements, disassembly thereof, and further reassembly, such as when reconfiguring an assembled building system.
Several alternative embodiments and examples have been described and illustrated herein. The embodiments of the invention described above are intended to be exemplary only. A person skilled in the art would appreciate the features of the individual embodiments, and the possible combinations and variations of the components. A person skilled in the art would further appreciate that any of the embodiments could be provided in any combination with the other embodiments disclosed herein. It is understood that the invention may be embodied in other specific forms without departing from the central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. Accordingly, while specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the scope of the invention as defined in the appended claims.
Patent Application
20180179749
