Modular Building System

Information

  • Patent Application
  • 20240295117
  • Publication Number
    20240295117
  • Date Filed
    March 01, 2024
    10 months ago
  • Date Published
    September 05, 2024
    4 months ago
  • Inventors
    • WEBSTER; Christopher
  • Original Assignees
    • WEBSTER PROPERTY GROUP, LLC (Lauderdale by the Sea, FL, US)
Abstract
Redefining modular construction, our Modular Building System surpasses existing methods of both traditional and modular construction. Every component, meticulously crafted such that it may be robotically produced and assembled, ensures unmatched precision and efficiency. Each panel, guarantees seamless integration and flawless finishes. Fully-finished in factory settings, they drastically simplify the construction process by eliminating many traditional materials and components, while retaining ease of construction and transportability from factory to building site, for final assembly. Our system's prowess extends to design flexibility, enabling construction of expansive living spaces with ease. Furthermore, its eco-conscious design facilitates effortless deconstruction and reuse, reducing environmental impact and waste. Revolutionizing the industry, this comprehensive solution heralds a new era of construction efficiency, adaptability, and sustainability, setting the standard for future developments, and aligning the construction industry more closely with modern automotive manufacturing and aerospace production industries.
Description
BACKGROUND OF THE INVENTION

Traditional construction methods, including off-site modular construction utilizing traditional building methods, often face challenges in terms of cost, construction time, transportation, design flexibility and the inability to integrate automated production-line processes. Often-times cost savings made by modular home manufacturers producing buildings in a controlled factory environment are eliminated by increased factory overhead and transportation costs. There is a need for innovative building systems that can be mass produced using automated production-line processes to address these challenges.


SUMMARY OF THE INVENTION

The Panelized Modular Building System described herein presents a solution by streamlining construction processes, where each component has been designed to be produced in such a manner that it may be manufactured and assembled at scale by automated robotic systems. The elements and components described herein may be designed with a profile so as to be conducive to roll forming and/or extrusion; for instance, part or all of the element(s)/component(s) may have a constant cross-section or profile so as to be capable of or conductive to these manufacturing processes. These processes can be very efficient from both cost and timing perspectives.


The Panelized Modular Building System as a whole has been carefully designed and analyzed in order to maintain a high level of construction efficiency, while retaining many benefits that traditional modular construction fails to address, such as design flexibility, the ability to construct large living spaces and the transportability of the building components to site.


The Panels comprising the Modular Building System herein have been designed such that they may be fully finished in a factory environment, including wall linings, finishes, exterior siding, flooring, plumbing, electrical and even the fitment of components such as light switches and power outlets before the panels leave the factory environment. This allows for entire walls, floors and roofs to be efficiently stacked and transported to site by truck, and installed in an extremely efficient manner, minimizing construction time and disturbance to the surrounding area.


This also addresses the issues faced by other panelized Modular Building Systems such as manual assembly of individual panels on-site, inability to provide smooth seamless wall structures, and manual finishing and installation of components after structural panels have been assembled on site.


The systems described herein have also been designed to deconstruct the same way that they are assembled, such that structures may be removed when they are no longer required, such that they can be re-used elsewhere, reducing environmental impact, minimizing waste, and greatly reducing the impact to the surrounding area.





DESCRIPTION OF THE FIGURES


FIG. 1 shows a Modular Building System according to one embodiment of the present disclosure.



FIG. 2 shows an exploded view of multiple embodiments comprising the Modular Building System of the present disclosure.



FIG. 3 shows an exploded view from another angle of multiple embodiments comprising the Modular Building System of the present disclosure, including the Internal Wall Lining Layer positioned on the internal facing side of the External Wall Panel.



FIG. 4 shows an External Wall Panel with Lower Exterior Wall Flashing fitted according to one embodiment the present disclosure.



FIG. 5 shows an exploded view of multiple embodiments comprising an External Wall Panel shown in FIG. 4 according to the present disclosure.



FIG. 6 shows an Individual Modular External Wall Panel according to one embodiment of the present disclosure.



FIG. 7 shows an exploded view of multiple embodiments comprising an Individual Modular External Wall Panel of the present disclosure.



FIG. 8 shows embodiments of the present disclosure, positioned to form a junction of two adjoining Individual Modular External Wall Panels, Steel Wall Stud, Vertical Connection Rod, and Weatherproof Connection Mechanism, shown before PU Foam is placed within the void.



FIG. 9 shows an Expanded Polystyrene (EPS) Foam Core, which comprises part of an Individual Modular External Wall Panel, with detail outlining the Service Channels and Strategically Profiled Edges, according to one embodiment of the present disclosure.



FIG. 10 shows embodiments of the present disclosure, positioned to form a junction of two adjoining Individual Modular External Wall Panels, Steel Wall Stud, Vertical Connection Rod, and Weatherproof Connection Mechanism, shown after PU Foam is placed within the void in order to create a weatherproof and structural connection between the Individual Modular External Wall Panels.



FIG. 11 shows the top edge of an External Wall Panel, with detail including the Weather-proof Seal featured in embodiments of the External Wall Panel.



FIG. 12 shows the top edge of an External Wall Panel, with detail shown of the Filler Holes featured in embodiments of the Upper Wall Bearing Plate, of the present disclosure.



FIG. 13 shows embodiments of the present disclosure, in an exploded view, of the bottom edge of an External Wall Panel, Lower Wall Bearing Plate, and the Lower Exterior Wall Flashing, with detail of the Vertical Profile of the Lower Wall Bearing Plate, shaped such that it may accept the upper edge of the Lower Exterior Wall Flashing upon assembly.



FIG. 14 shows embodiments of the assembled Modular Building System, in particular a detailed view of the corner of the assembly, where embodiments of an upper level and a lower level, featuring External Wall Panels are adjoining to a Mid-floor panel, with detail shown of the External Wall Connection Brackets adjoining said panels, and Lower Exterior Wall Flashing embodiments positioned in place.



FIG. 15 shows the top bottom edge of an External Wall Panel, with Lower Exterior Wall Flashing fitted, also showing detail including the Lower Weather-proof Seal, featured in embodiments of the External Wall Panel.



FIG. 16 shows a Weatherproof Connection Mechanism, according to one embodiment of the External Wall Panel of the present disclosure.



FIG. 17 shows a Metal Siding Layer, according to one embodiment of the Individual Modular External Wall Panel, of the External Wall Panel of the present disclosure.



FIG. 18 shows embodiments of two adjoining Individual Modular External Wall Panels, with the EPS Foam Cores not shown, to outline the continuous weatherproof siding layer created by positioning of the embodiments of the two adjoining Metal Siding Layers, of the adjoining Individual Modular External Wall Panels, connected by means of the Weatherproof Connection Mechanism, as well as the position of the Steel Wall Stud relative to Individual Modular External Wall Panels of the present disclosure.



FIG. 19 shows a Steel Wall Stud, according to one embodiment of the External Wall Panel of the present disclosure.



FIG. 20 shows a Vertical Connection Rod, according to one embodiment of the present disclosure.



FIG. 21 shows embodiments of two adjoining External Wall Panels, are connecting to a Mid-floor Panel, with detail shown of the connection between the Vertical Connection Rods and the External Wall Connection Brackets, as well detail of the External Vertical Connection Rods adjoining said Mid-floor Panel.



FIG. 22 shows embodiments of an External Wall Panel located on the upper level of the assembled Modular Building System, and an External Wall Panel located on the lower level of an assembled Modular Building System, with detail shown of the connection between the Vertical Connection Rods of both External Wall Panels, to the adjoining External Wall Connection Bracket, such that a continuous vertical connection is formed between each of the embodiments shown.



FIG. 23 shows embodiments of an External Wall Panel located on the lower level of an assembled Modular Building System, with detail shown of the connection between the Vertical Connection Rods of the External Wall Panel, to the adjoining External Wall Connection Bracket, such that a continuous vertical connection is formed between from the External Wall Panel located on the lower level of an assembled Modular Building System, down to the External Wall Connection Bracket.



FIG. 24 shows embodiments of an exploded view of an External Wall Panel connecting to an Internal Wall Panel, by means of Male Joining Mechanisms located on the External Wall Panel, and Female Joining Mechanisms located on the Internal Wall Panel.



FIG. 25 shows a detailed view of embodiments of an exploded view of an External Wall Panel connecting to an Internal Wall Panel, by means of Male Joining Mechanisms located on the External Wall Panel, and Female Joining Mechanisms located on the Internal Wall Panel, as also shown in FIG. 24.



FIG. 26 shows a close up detailed view of embodiments of an exploded view of an External Wall Panel connecting to an Internal Wall Panel, by means of Male Joining Mechanisms located on the External Wall Panel, and Female Joining Mechanisms located on the Internal Wall Panel, as also shown in FIG. 24 and FIG. 25.



FIG. 27 shows an Internal Wall Panel according to one embodiment of the present disclosure.



FIG. 28 shows an exploded view of multiple embodiments comprising an Internal Wall Panel of the present disclosure, including the Internal Wall Lining Layers, located on each side of the Internal Wall Panel.



FIG. 29 shows an Individual Modular Internal Wall Panel according to one embodiment of the present disclosure.



FIG. 30 shows an exploded view of multiple embodiments comprising an Individual Modular Internal Wall Panel of the present disclosure.



FIG. 31 shows an Expanded Polystyrene (EPS) Foam Core, which comprises part of an Individual Modular Internal Wall Panel, with detail outlining the Service Channels, according to one embodiment of the present disclosure.



FIG. 32 shows an Individual Modular Internal Wall Panel, with detail outlining the Service Channels and Strategically Profiled Edges, according to one embodiment of the present disclosure.



FIG. 33 shows embodiments of the present disclosure, positioned to form a junction of two adjoining Individual Modular Internal Wall Panels, Steel Wall Studs and Internal Vertical Connection Rod, shown before PU Foam is placed within the void in order to create a connection between the Individual Modular Internal Wall Panels, whereby the Internal Vertical Connection Rod forms part of a Pinned Connection upon final assembly of the Modular Building System.



FIG. 34 shows embodiments of the present disclosure, positioned to form a junction of two adjoining Individual Modular Internal Wall Panels, Steel Wall Studs and Internal Vertical Connection Rod, shown after PU Foam is placed within the void in order to create a connection between the Individual Modular Internal Wall Panels.



FIG. 35 shows the top edge of an Internal Wall Panel, with detail shown of the Strategically Positioned Filler Holes featured in embodiments of the Upper Internal Wall Bearing Plate, of the present disclosure.



FIG. 36 shows embodiments of the lower edge of an Internal Wall Panel, and Floor Panel with detail shown of the lower end of the Internal Vertical Connection Rod, and the Strategically Placed Holes positioned in the top face of the Floor Panel, such that when the Internal Vertical Connection Rods are positioned within the Strategically Positioned Holes featured in the said Floor Panel, a pinned connection can be formed between said panels.



FIG. 37 shows a Floor Panel according to one embodiment the present disclosure.



FIG. 38 shows an exploded view of multiple embodiments comprising Floor Panel shown in FIG. 37 according to the present disclosure.



FIG. 39 shows an Expanded Polystyrene (EPS) Foam Core, which comprises part of a Floor Panel, with detail outlining the Strategically Profiled Edges, according to one embodiment of the present disclosure.



FIG. 40 shows a Female Steel Floor Joist, according to one embodiment of the present disclosure, with detail showing Female Inter-floor Locking Mechanisms included in the embodiment of the Female Steel Floor Joist.



FIG. 41 shows a Male Steel Floor Joist, according to one embodiment of the present disclosure, with detail showing Male Inter-floor Locking Mechanisms included in the embodiment of the Male Steel Floor Joist.



FIG. 42 shows embodiments of an EPS foam Core of a Floor Panel, with a Male Steel Floor Joist positioned against the Strategically Profiled Edge of the EPS Foam Core, before PU Foam is applied to the Void located between the EPS foam Core and the Male Steel Floor Joist to form a connection between said embodiments.



FIG. 43 shows embodiments of an EPS foam Core of a Floor Panel, with a Male Steel Floor Joist, and Female Steel Floor Joist, that have been attached by means of filling the Voids between the Steel Floor Joists and the EPS foam Core with PU Foam, and allowing the PU Foam to cure.



FIG. 44 shows embodiments of a Female Steel Floor Joist attached to an EPS foam Core of a Floor Panel, with detail showing Filler Holes positioned along the Steel Floor Joist such that they may be used to inject liquid PU Foam into the Void situated between the Steel Floor Joist and the EPS Foam Core.



FIG. 45 shows a Metal Lower Layer, which comprises part of a Floor Panel, one embodiment of the present disclosure.



FIG. 46 shows an Upper Structural Floor Board Layer, comprised of multiple structural board embodiments, arranged to form a long flat surface, which comprises part of a Floor Panel, of the present disclosure.



FIG. 47 shows embodiments of a Female Inter-floor Locking Mechanism, which is featured on the face of a Female Steel Floor Joist, with detail showing the embodiments of the Key Shaped Slot and Angular Tabs comprising the Female Inter-floor Locking Mechanism.



FIG. 48 shows embodiments of a Male Inter-floor Locking Mechanism which is inserted into a Female Inter-floor Locking Mechanism, where the Inter-floor Locking Mechanism is situated in the Open Position, before the inter-locking Floor Panels, Mid-floor Panels or Roof Panels are moved into their final positions, moving the Inter-floor Locking Mechanism into the Locked position, creating a connection between the two adjoining Floor Panels, Mid-floor Panels or Roof Panels.



FIG. 49 shows embodiments of the Male Inter-floor Locking Mechanism and Female Inter-floor Locking Mechanism shown in FIG. 47, where the Inter-floor Locking Mechanism is situated in the Closed Position, where the inter-locking Floor Panels, Mid-floor Panels or Roof Panels have been moved into their final positions, moving the Inter-floor Locking Mechanism from the Open into the Locked position, creating a connection between the two adjoining Floor Panels, Mid-floor Panels or Roof Panels.



FIG. 50 shows embodiments of two adjoining Floor Panels, which have been connected by means of the Inter-Floor Locking Mechanisms.



FIG. 51 shows a Mid-floor Panel according to one embodiment of the present disclosure.



FIG. 52 shows an exploded view of multiple embodiments comprising Mid-floor Panel shown in FIG. 51 according to the present disclosure, whereby the embodiments included to form the layers of the Mid-floor Panel are different to that of the Floor Panel, such that requirements for a lower ceiling surface may be accommodated.



FIG. 53 shows a Roof Panel according to one embodiment the present disclosure.



FIG. 54 shows an exploded view of multiple embodiments comprising Roof Panel shown in FIG. 53 according to the present disclosure, whereby the embodiments included to form the layers of the Roof Panel are different to that of the Floor Panel, such that requirements for a lower ceiling surface, and a Metal Upper Structural Layer may be accommodated.



FIG. 55 shows embodiments of a Modular Building System, including embodiments of a Roof Panel, a Mid-floor Panel, and Window Panels according to multiple embodiments of the present disclosure, with detail outlining the Structural Frame, the Non-structural Window or Door Component, and the Strategically Shaped Vertical Window Profile which comprise the Window Panel.



FIG. 56 shows a Window Panel according to one embodiment of the present disclosure.



FIG. 57 shows an embodiment of a Structural Metal Frame which comprises part of the Window Panel according to the present disclosure.



FIG. 58 shows an embodiment of a Non-structural Window or Door Component which comprises part of the Window Panel according to the present disclosure.



FIG. 59 shows embodiments of a Window Panel, attached to an Individual Modular External Wall Panel on each side, by means of a Weatherproof Connection Mechanism adjoining the Metal Siding Layers of the Individual Modular External Wall Panels to the Strategically Shaped Vertical Window Profiles, with the addition of PU Foam positioned in the Voids formed between the Window Panel and the Individual Modular External Wall Panels.



FIG. 60 shows cross sectional views of the embodiments of a Window Panel, with specific detail showing the Strategically Shaped Vertical Window Profiles, Structural Metal Frame, and Non-structural Window or Door Component.



FIG. 61 shows embodiments of a Window Panel attached to an Individual Modular External Wall Panel, whereby the void between two said panels has been filled with PU Foam, allowing a weathertight and structural connection to be formed between the Structural Metal Frame, the Non-structural Window or Door Component, and the Individual Modular External Wall Panel, upon curing of the PU Foam, and also showing detail of the Weatherproof Connection Mechanism interlocking with the embodiment of the Strategically Shaped Vertical Window Profile,



FIG. 62 shows embodiments of a the lower section of a Window Panel, with detail showing the Lower Horizontal Profile of the Non-Structural Window or Door Component, with another embodiment shown of a Lower External Wall Flashing fitted to the bottom of the Window Panel.



FIG. 63 shows embodiments of a Window Panel, with Upper Exterior Wall Flashings and Lower Exterior Wall Flashings fitted, with detail shown of Male Connection Mechanisms fitted to the Structural Metal Frame of the Window Panel, such that it may attach to embodiments of adjoining Floor-panels, Midfloor-panels or Roof Panels.



FIG. 64 shows a detailed view of embodiments of a Window Panel, attached to an adjoining Roof panel, with detail of Male Inter-floor Locking Mechanisms, and Female Inter-floor Locking Mechanisms utilized to form a connection between said panels.



FIG. 65 shows a detailed view of embodiments of a Window Panel, attached to an adjoining Floor panel, with detail shown of the Window Panel finished height being below the Floor Panel interior finished height, such that door sliding tracks or other components may be recessed below the finished floor level, such that an even transition may be maintained between the interior and exterior of the Modular Building System



FIG. 66 shows embodiments comprising a Structural Floor Joining Bracket of the present disclosure.



FIG. 67 shows an exploded view of multiple embodiments, showing an Internal Wall Panel, and the embodiments comprising the Structural Floor Joining Bracket of the present disclosure, which consist of the Rectangular Hollow Section and Sliding Locking Plate.



FIG. 68 shows an embodiment of a Rectangular Hollow Section which comprises part of a Structural Floor Joining Bracket of the present disclosure.



FIG. 69 shows an embodiment of a Sliding Locking Plate which comprises part of a Structural Floor Joining Bracket of the present disclosure.



FIG. 70 shows an embodiment of an Internal Wall Panel, with detail shown of the Internal Vertical Connection Rods featuring Disc Shaped Ends, which form the Male Inter-locking Mechanism that interacts with the Sliding Locking Plate of the Structural Floor Joining Bracket when a connection is made between said embodiments within the present disclosure.



FIG. 71 shows embodiments of an Internal Wall Panel, and the Structural Floor Joining Bracket, with detail shown of the positioning of the Internal Vertical Connection Rods featuring Disc Shaped Ends situated in the Internal Wall Panel, relative to the Strategically Placed Holes situated in the Rectangular Hollow Section, which combined with the Sliding Locking Plate, form the Structural Floor Joining Bracket, where details of the Access Points of the Structural Floor Joining Bracket are also shown.



FIG. 72 shows embodiments of the Structural Floor Joining Bracket, with detail shown of the positioning of the Sliding Locking Plate relative to the Rectangular Hollow Section, such that the Structural Floor Joining Bracket is positioned in the Open Position, allowing the acceptance of the Internal Vertical Connection Rods featuring Disc Shaped Ends.



FIG. 73 shows embodiments of the Structural Floor Joining Bracket, with detail shown of the positioning of the Sliding Locking Plate relative to the Rectangular Hollow Section, such that the Structural Floor Joining Bracket is positioned in the Closed Position, causing the Disc Shaped Ends of the Internal Vertical Connection Rods to become captive within the Structural Floor Joining Bracket if the Closed Position is achieved while the Internal Vertical Connection Rods featuring Disc Shaped Ends are inserted into the Structural Floor Joining Bracket.



FIG. 74 shows embodiments of the Sliding Locking Plate, which forms part of the Structural Floor Joining Bracket, with detail shown of the Key Shaped Slots, and Tapered Inward Sloping Edges.



FIG. 75 shows embodiments of the Structural Floor Joining Bracket and an Internal Wall Panel, with detail shown of the Internal Vertical Connection Rods featuring Disc Shaped Ends inserted into the Structural Floor Joining Bracket as it is situated in the Open Position.



FIG. 76 shows embodiments of the Structural Floor Joining Bracket, with detail shown of the Internal Vertical Connection Rods featuring Disc Shaped Ends inserted into the Structural Floor Joining Bracket as it is situated in the Closed Position, causing the Disc Shaped Ends of the Internal Vertical Connection Rods to become captive, and a tensioned connection to be formed between the Internal Wall Panel that the Internal Connections Rods are situated within, and the Structural Floor Joining Bracket.



FIG. 77 shows embodiments of the Structural Floor Joining Bracket fastened to adjoining Mid-floor Panels, and Internal Wall Panels both above and below the Structural Floor Joining Bracket, such that a structural connection may be formed between said panels.



FIG. 78 shows embodiments of two adjoining External Wall Panels, that are connecting to a Roof Panel, by means of an External Wall Connection Bracket, with detail shown of the connection between the External Wall Panels and the External Wall Connection Bracket, and the adjoining Roof Panel, and the positioning of the External Wall Panel, relative to the Roof Panel.



FIG. 79 shows embodiments of an upper level External Wall Panel and a Lower level External Wall Panel, that are connecting to a Mid-Floor Panel, by means of an External Wall Connection Bracket, with detail shown of the connection between the External Wall Panels and the External Wall Connection Bracket, and the adjoining Mid-floor Panel, and the positioning of the External Wall Panels, relative to the Mid-floor Panel, and also showing detail of the continuous structural connection formed between the said panels by means of the Vertical Connection Rods and the External Wall Connection Bracket.



FIG. 80 shows embodiments of External Wall Panels attached to Floor Panels by means of External Wall Connection Brackets, and outlines the positioning of the External Wall Panels, relative to the Floor Panels, such that increments of full panel widths are maintained within the internal floor area.



FIG. 81 shows an exploded view of embodiments comprising an Exterior Wall Butt Joining Bracket, as well as adjoining External Wall Panels and Internal Wall Panels.



FIG. 82 shows an embodiment of the Structural U Shaped Bracket, which comprises an embodiment of an Exterior Wall Butt Joining Bracket.



FIG. 83 shows an embodiment of the Straight External Wall Panel Siding Joiner, which comprises an embodiment of an Exterior Wall Butt Joining Bracket.



FIG. 84 shows a detailed view of embodiments comprising an assembled Exterior Wall Butt Joining Bracket.



FIG. 85 shows a view of embodiments comprising an Exterior Wall Corner Bracket, as well as adjoining External Wall Panels, Roof Panel, and Mid Floor Panel, and adjoining External Wall Panel Joining Brackets.



FIG. 86 shows an embodiment of the Structural L Shaped Bracket, which comprises an embodiment of an Exterior Wall Corner Bracket.



FIG. 87 shows an embodiment of the Structural L Shaped Bracket, which has been attached to adjoining External Wall Panels, such that a structural connection is made between said panels.



FIG. 88 shows an embodiment of the Boxed Corner Siding Joiner, which comprises an embodiment of an Exterior Wall Corner Bracket.



FIG. 89 shows embodiments of an assembled Exterior Wall Corner Bracket, forming a structural and weathertight connection between adjoining Exterior Wall Panels at the corner of an assembled structure comprised of the Modular Building System.



FIG. 90 shows embodiments of an assembled Foundation System, with connecting Floor Panels, External Wall Panels and Internal Wall Panels.



FIG. 91 shows an exploded view of FIG. 90, including embodiments of a Foundation System, with Floor Panels, External Wall Panels and Internal Wall Panels.



FIG. 92 shows embodiments comprising an assembled Foundation System, consisting of Helical Screw Pile Foundations, Flexible Foundation Mounting Brackets and Structural Floor Bearers.



FIG. 93 shows an exploded view of embodiments comprising an assembled Foundation System in FIG. 92, consisting of Helical Screw Pile Foundations, Flexible Foundation Mounting Brackets and Structural Floor Bearers.



FIG. 94 shows embodiments comprising a Structural Floor Bearer, comprised of a Rectangular Hollow section featuring a Bearer Slot, and a Sliding Locking Plate.



FIG. 95 shows embodiments comprising a Flexible Foundation Mounting Bracket, comprised of a Rubber Bearing Pad, Upper Bracket Plate, Mounting Bolts and a Rod or Bolt and Fastening Nut.



FIG. 96 shows embodiments comprising a Helical Screw Pile Foundation, comprised of a Helical Screw Pile and Mounting Plates featuring Slots such that multiple mounting positions can be achieved.



FIG. 97 shows embodiments comprising a Helical Screw Pile, Flexible Foundation Mounting Bracket and Structural Floor Bearer, with detail shown of the Slots in the Mounting Plate of the Helical Screw Pile, and Bearer Slots within the Structural Floor Bearer, showing how multiple positions of fastening may be achieved by adjusting the Mounting Bolts and Bolt or Nut within said slots.



FIG. 98 shows embodiments of an assembled Roofing System, comprising of Roof Panels, Roof Anchor Brackets, Foldable Roof Trusses, Snap Together Roofing Purlins and a Snap on Metal Roofing Layer.



FIG. 99 shows an exploded view of FIG. 98, where embodiments of an assembled Roofing System, comprising of Roof Panels, Roof Anchor Brackets, Foldable Roof Trusses, Snap Together Roofing Purlins and a Snap on Metal Roofing Layer are shown.



FIG. 100 shows an embodiment of a Roof Anchor Bracket which comprises one embodiment of the Roofing System, with detail shown of the Anchor Cut-outs and Truss Connection Cut-outs.



FIG. 101 shows multiple embodiments of the Roofing System, comprising of the Roof Anchor Bracket, attached to the Roof Panels, The Foldable Roof Truss attached to the Roof Anchor Bracket, with detail shown of the Roof Anchor Clips inserted into the Anchor Cut-outs, the Truss Connection Tabs inserted into the Truss Connection Cut-outs, and the Purlin Connection Tabs, as well as the Pinned Connection of the Foldable Roof Truss.



FIG. 102 shows an embodiments a the Foldable Roof Truss, which is comprised of the Sloping Member attached to various Supporting Member Embodiments, via a Pinned connection, whereby the Foldable Roof Truss is shown in the folded position, allowing for efficient transportation of said Foldable Roof Truss.



FIG. 103 shows an embodiments a the Foldable Roof Truss, which is comprised of the Sloping Member attached to various Supporting Member Embodiments, via a Pinned connection, whereby the Foldable Roof Truss is shown in the un-folded position, allowing for assembly of the Roofing System on site, utilizing said Foldable Roof Truss.



FIG. 104 shows multiple embodiments of the Roofing System, comprising of the Roof Anchor Bracket, attached to the Roof Panels, and the Foldable Roof Truss attached to the Roof Anchor Bracket, with detail shown of the Roof Anchor Clips inserted into the Anchor Cut-outs, and the Truss Connection Tabs inserted into the Truss Connection Cut-outs.



FIG. 105 shows an embodiment of a Snap Together Roofing Purlin, with detail shown of the Snap-on Roof Layer Connection Hooks, which form the connection between the Snap Together Roofing Purlin and the Snap On Metal Roofing Layer.



FIG. 106 shows embodiments of a Snap Together Roofing Purlin attached to multiple Foldable Roof Trusses, with detail shown of the connection between the Snap Together Roofing Purlin and the Foldable Roof Trusses, via the Purlin Connection Tabs.



FIG. 107 shows an embodiment of a Snap On Metal Roofing Layer, with detail shown of the Male Profile and Female Hook of the said Snap on Metal Roofing Layer.



FIG. 108 shows an exploded view of a connection between two embodiments of Snap On Metal Roofing Layers, with detail shown of the Male Profile positioning underneath the Female Hook, before final placement of the Snap on Metal Roofing Layers are made.



FIG. 109 shows multiple embodiments of a partially assembled Roofing System, with cross sectional details shown on the left of the figure, of two embodiments of Snap On Metal Roofing Layers, attached to one embodiment of a Snap Together Roofing Purlin, detailing the interaction and connection between the Female Hook of one Snap On Metal Roofing Layer, attaching to the Snap-on Roof Layer Connection Hooks of a Snap Together Roofing Purlin, which holds captive the Male Profile of an adjoining Snap On Metal Roofing Layer, and on the right of the figure, the Connection Hooks of the Snap Together Roofing Purlin, holding the Male Profile of the initial Snap On Metal Roofing Layer captive, such that a connection is formed between the Snap Together Roofing Purlin, and the Snap On Metal Roofing Layer.



FIG. 110 shows an assembled Snap On Metal Roofing Layer, comprised of multiple embodiments of said individual Snap on Metal Roofing Layers.



FIG. 111 shows multiple embodiments comprising part of the Decorative Siding System, comprising part of an External Wall Panel, whereby multiple Substitute WeatherProof Connection Mechanisms are positioned within the External Wall Panel, and Siding Mounting Battens are attached to the WeatherProof Connection Mechanisms.



FIG. 112 shows an exploded view of multiple embodiments comprising the Decorative Siding System, comprising part of an External Wall Panel, whereby multiple Substitute WeatherProof Connection Mechanisms are positioned within the External Wall Panel, and multiple embodiments of the Siding Mounting Battens and Decorative Siding Panels are shown.



FIG. 113 shows a detailed view of an embodiment of part of an External Wall Panel, whereby a Substitute WeatherProof Connection Mechanism has been positioned within the External Wall Panel, such that with the addition of PU Foam, a weathertight and structural connection is formed between two adjoining Individual Modular External Wall Panels, which include the embodiment of the Substitute WeatherProof Connection Mechanism, where the Siding Mounting Battens and Decorative Siding Panels may then be attached.



FIG. 114 shows the upper portion of an embodiment of a Substitute WeatherProof Connection Mechanism, with detail shown of the Mounting Cut-outs, situated on the Mounting Surface of said Substitute WeatherProof Connection Mechanism.



FIG. 115 an embodiment of a Siding Mounting Batten, with detail shown of the Siding Clip Cutouts, situated on said Siding Mounting Batten.



FIG. 116 shows a portion of an embodiment of a Siding Mounting Batten, with detail shown of the Siding Clip Cutouts, and Batten Mounting Tabs situated on said Siding Mounting Batten.



FIG. 117 shows multiple embodiments comprising part of the Decorative Siding System, with detail shown of a Siding mounting Bracket attached to a Substitute WeatherProof Connection Mechanism by means of the Batten Mounting Tabs inserted into the Mounting Cut-outs are positioned on said Siding Mounting Batten.



FIG. 118 shows an embodiment of a Decorative Siding panel with Decorative Siding Clips attached.



FIG. 119 shows a detailed partially exploded view of embodiments comprising the Decorative Siding System, whereby multiple Substitute WeatherProof Connection Mechanisms are positioned within an External Wall Panel, and multiple Siding Mounting Battens are attached to said Substitute WeatherProof Connection Mechanisms, and an embodiment of a Decorative Siding Panel is shown, with detail included of the Decorative Siding Clips featuring Male Siding Clip Hooks and the Siding Clip Cutouts located on the Siding Mounting Battens.



FIG. 120 shows an alternative view of FIG. 119, whereby a detailed partially exploded view of embodiments comprising the Decorative Siding System, whereby multiple Substitute WeatherProof Connection Mechanisms are positioned within an External Wall Panel, and multiple Siding Mounting Battens are attached to said Substitute WeatherProof Connection Mechanisms, and an embodiment of a Decorative Siding Panel is shown, with detail included of the Decorative Siding Clips and the Siding Clip Cutouts located on the Siding Mounting Battens.



FIG. 121 shows partially assembled embodiments comprising the Decorative Siding System, whereby a single embodiment of a Decorative Siding Panel, is attached to an embodiment of an External Wall Panel featuring multiple Substitute WeatherProof Connection Mechanisms fitted, and multiple Siding Mounting Battens are attached to said Substitute WeatherProof Connection Mechanisms.



FIG. 122 shows embodiments of an assembled Decorative Siding System, whereby a multiple Decorative Siding Panel embodiments are attached to an External Wall Panel featuring the Decorative Siding System applied.



FIG. 123 shows a single embodiment of a Modular Building System disclosed herein, describing one of many possible configurations of the Modular Building System, and hence outlining the flexibility of structure design that may be achieved by the Modular Building System described herein.





DETAILED DESCRIPTION

With reference to the drawings, in particular to FIG. 1, FIG. 2 and FIG. 3, embodiments of the present disclosure may include a Modular Building System 1, including a panelized construction method utilizing interlocking mechanisms for joining various panels, the panels including External Wall Panels 2, Internal Wall Panels 3, Floor Panels 4, Mid-Floor Panels 5, Roof Panels 6, Window Panels 7, Structural Floor Joining Brackets 9, External Wall Connection Brackets 10, Exterior Wall Butt Joining Brackets 11, Exterior Wall Corner Brackets 12, Lower Exterior Wall Flashings 13, Upper Exterior Wall Flashings 14, and may include the addition of a Foundation System 15, Roofing System 8, and or the Decorative Siding System 17 described herein. It should be understood that any combination of these and other elements is possible.


With reference to the drawings, in particular to FIG. 4 to FIG. 5 and FIG. 6, embodiments may also include The Modular Building System 1, described herein, in some embodiments, the External Wall Panels may be further comprised of Individual Modular External Wall Panels 18, Weatherproof Connection Mechanisms 19, Upper Wall Bearing Plates 20, Lower Wall Bearing Plates 21, Steel Wall Studs 22 and Vertical Connection Rods 23, may be all connected together using Polyurethane (PU) Foam 24, featuring an Internal Wall Lining Layer 25, to form a weatherproof, structural, assembled wall up to a desired length.


With reference to the drawings, in particular to FIG. 6 and FIG. 7, Embodiments of the Individual Modular External Wall Panels 18 may be further comprised of a Foam Expanded Polystyrene (EPS) Core 26 sandwiched and glued between a strategically profiled Metal Siding Layer 27 outlined in FIG. 7, and an Internal Lining Board 28. It should be understood that any combination of these and other elements is possible.


With reference to the drawings, in particular to FIG. 8 and FIG. 9, in some embodiments, the EPS Foam Core 26 may feature strategically placed Service Channels 29 located on the inner facing side as outlined in FIG. 8 and FIG. 9, such that, when fixed to the Internal Lining Board 28, Cavities may be created by the Service Channels 29, such that services such as pipes and wires may be located within the Cavities described herein.


With reference to the drawings, in particular to FIG. 8 and FIG. 9, in some embodiments, the EPS Foam Core 26 features Strategically Profiled Edges 16, such that when positioned next to an adjoining Individual Modular External Wall Panel 18, the Steel Wall Stud 22 positioned at the juncture of the Internal Lining Boards 28 may be held captive, as outlined in FIG. 8 and therefore may be positioned without the use of alternative fastening means.


With reference to the drawings, in particular to FIG. 8 and FIG. 10, in some embodiments, the EPS Foam Core 26, features a smaller width than the Internal Lining Board 28, and the strategically profiled Metal Siding Layer 27, creating a Void 30 in-between adjoining Individual Modular External Wall Panels 18, embodiments may be shaped such that this Void 30, may be filled with PU Foam 24, as outlined in FIG. 10, such that once the PU foam 24, has been allowed to cure, a structural and weathertight bond may be formed in-between the two adjoining Individual Modular External Wall Panels 18.


With reference to the drawings, in particular to FIG. 8, in some embodiments, the strategically profiled Metal Siding Layer 27, features a profile, such that it may interlock with the Weatherproof Connection Mechanism 19, to form an inward facing connection, sometimes referred to as a negative detail, at the juncture between two Individual Modular External Wall Panels.


With reference to the drawings, in particular to FIG. 11 In some embodiments, the Upper Wall Bearing Plate 20, features a Weather-proof Seal 31, such that a weatherproof and airtight seal may be formed at the juncture of the top of an External Wall Panel 2, and the Roof Panel 6 or Mid-Floor Panel 5, that may be resting on the External Wall Panel 2 after final assembly.


With reference to the drawings, in particular to FIG. 12, In some embodiments, the Upper Wall Bearing Plate 20, may feature strategically positioned Filler Holes 32, that allow the voids in-between adjoining Individual Modular External Wall Panels 18 to be filled with PU Foam 24, allowing the Upper Wall Bearing Plate 20, the Lower Wall Bearing Plate 21, and the two adjoining Individual Modular External Wall Panels 18, to become structurally adjoined by the PU foam 24.


With reference to the drawings, in particular to FIG. 13 and FIG. 14, the Lower Bearing Plate 19, may feature a Vertical Profile 33, such that a strategically positioned slot may be created along the bottom edge of the External Wall Panel 2, such that a Lower Exterior Wall Flashing 13, may be inserted into the slot which can then extend below the finished height of the Floor Panel 4, or Mid-Floor Panel 5, below the External Wall Panel 2, creating a weatherproof transition between the External Wall Panel 2, and the adjoining Floor Panel 4 or Mid-Floor Panel 5 and also any External Wall Panel 2, that may be situated below such Floor Panel 4 or Mid-Floor Panel 5, which may be connected by an External Wall Connection Bracket 10.


With reference to the drawings, in particular to FIG. 15, embodiments of the External Wall Panel 2, and more specifically, the Lower Wall Bearing Plate 21 may feature a Lower Weather-proof Seal 34, such that a weatherproof and airtight seal may be formed at the juncture of the bottom of an External Wall Panel 2, and the Floor Panel 4, or Mid-Floor Panel 5, that the External Wall Panel 2, may be resting on after final assembly, connected by means of an External Wall Connection Bracket 10.


With reference to the drawings, in particular to FIG. 16, FIG. 17, and FIG. 18, embodiments may also include the Weatherproof Connection Mechanisms 19, may be strategically profiled in such a manner that they may be able to interlock with the strategically profiled Metal Siding Layers 27 of adjoining Individual Modular External Wall Panels 18, as outlined in FIG. 18, such that the embodiments may form continuous Metal Siding Layer in-between adjoining Individual Modular External Wall Panels 18.


With reference to the drawings, in particular to FIG. 4, FIG. 8, FIG. 18, and FIG. 19, embodiments may also include the Steel Wall Stud 22, which may be strategically positioned such that when fastened to the Internal Lining Boards 28, of both adjoining Individual Modular External Wall Panels 18, a smooth transition may be created on the inner face of the adjoining Internal Lining Boards 28.


With reference to the drawings, in particular to FIG. 5, FIG. 8 and FIG. 10, the Steel Wall Stud 22 may be strategically positioned in such a manner that the intersection, between adjoining Internal Lining Boards 28, between two adjoining Individual Modular External Wall Panels 18, becomes enclosed, and where the Weatherproof Connection Mechanism 19 interlocks with the Metal Siding Layers 27, of the mentioned Individual Modular External Wall Panels 18, such that when the Upper Wall Bearing Plate 20 and the Lower Wall Bearing Plate 21 may be fitted, the void created at the junction of two adjoining Individual Modular External Wall Panels 18, may become sealed, allowing the void to be filled with PU Foam 24, while being contained.


With reference to the drawings, in particular to FIG. 8 and FIG. 10, in some embodiments, the PU Foam 24, may be strategically positioned in order to provide additional structural integrity to the Steel Wall Stud 22, by interlocking with the Steel Wall Stud 22, which may enhance the structural performance of the Steel Wall Stud 22, by providing lateral support to the wall stud 22, which may help to preventing buckling under extreme load conditions.


With reference to the drawings, in particular to FIG. 8 and FIG. 10, in some embodiments, the PU Foam 24, foam may be strategically positioned in order to provide additional protection against fire or heat, to the Steel Wall Stud 22, and any services, including but not limited to, pipes, wires, ducts or other, which may be located within the External Wall Panel 2.


With reference to the drawings, in particular to FIG. 5 and FIG. 10, in some embodiments, the PU Foam 24, and the EPS Foam Core 26, may be strategically shaped and positioned such that the PU Foam 24, may be only be situated where it may be required for both structural joining of the other External Wall Panel 2 members, and where weatherproof joins may be required at the junction between Individual Modular External Wall Panels 18, such that the more cost effective EPS foam Core 26, may be utilized to form the majority of the volume of the External Wall Panel 2, such that manufacturing costs may be dramatically reduced, which may create the difference in cost for the Modular Building System 1 to become price competitive with traditional and other types of modular construction and hence viable in a market.


With reference to the drawings, in particular to FIG. 8, FIG. 20, FIG. 21, FIG. 22 and FIG. 23, embodiments may also include the Vertical Connection Rod 23, which may be comprised of a structural metal rod, which may be threaded at each end, such that it may be strategically positioned vertically within the External wall panel 2, such that the PU Foam 24, may secure it in place, and a continuous structural connection may be formed between each layer of the Modular Building System 1, which may utilize a Roof Panel to External Wall Panel Connection 35, an External Wall Panel to Mid-floor Panel Connection 36, a Mid-Floor to External Wall Connection 37, and an External Wall Panel to Floor Panel Connection 38, such that load may be distributed from each part of the structure into the Foundation System 15, of the building.


With reference to the drawings, in particular to FIG. 4, and FIG. 5, embodiments of the External Wall Panel 2, may include some embodiments, such as the Internal Wall Lining Layer 25, which may be fixed to the inside face of an External Wall Panel 2, with the lining material featuring a strategic width and thickness, such that the material width may be equal or greater than the height of the External Wall Panel 2, and a thickness may be sufficient such that it may cover imperfections on the internal face of the External Wall Panel 2, such that, combined with the Steel Wall Studs 22, fastening the Internal Lining Boards 28, such that a flat surface may be maintained at the juncture between them, the Internal Wall Lining Layer 25, may be applied to the entire internal surface of the Assembled External Wall Panel 2, by means of adhesive or other fastening, providing a flat and smooth internal lining surface, eliminating the need for further traditional surface finishing processes including but not limited to; DryWall application, DryWall joint compound application, Drywall skimming, surface priming and painting.


With reference to the drawings, in particular to FIG. 24, FIG. 25, and FIG. 26, External Wall Panels 2, and Internal Wall Panels 3, may also include the modification or addition of Male Joining Mechanisms 39, or Female Joining Mechanisms 40 as detailed in, allowing for a structural attachment to be made between Internal Wall Panels 3, and External Wall Panels 2, while the Internal Lining Layer 25, of the External Wall Panel 2, and External Metal Siding Layer 27, of the External Wall Panel 2, and both Internal Wall Lining Layers 41, of the Internal Wall Panel 3, remain in-tact.


With reference to the drawings, in particular to FIG. 27, FIG. 28, and FIG. 29, embodiments of the present disclosure may also include the Internal Wall Panel 3, and embodiments of the Internal Wall Panel 3, may also be further comprised of Individual Modular Internal Wall Panels 42, as referenced in FIG. 28, of which the Individual Modular Internal Wall Panels 42 may be further comprised of Upper Internal Wall Bearing Plates 43, Lower Internal Wall Bearing Plate 44, Steel Wall Studs 22, and Internal Vertical Connection Rods 45, may be all connected together using Polyurethane (PU) Foam 24, featuring an Internal Wall Lining Layer 41, on each side, to form, pre-finished Internal Wall Panels 3, walls up to a desired length, as referenced in FIG. 28.


With reference to the drawings, in particular to FIG. 29, FIG. 30, the Individual Modular Internal Wall Panels 42, may be further comprised of an Expanded Polystyrene (EPS) Foam Core 46, sandwiched and glued between two Internal Lining boards 47.


With reference to the drawings, in particular to FIG. 31, FIG. 32, in some embodiments, the EPS Foam Core 46, may feature Strategically Placed Channels on both sides 48, such that, when fixed to the Internal Lining Boards 47, Service Cavities 49, may be created on either side such that services such as pipes, wires and other services may be located within each side of the wall.


With reference to the drawings, in particular to FIG. 32 and FIG. 33, in some embodiments, the EPS Foam Core 46, of the Individual Modular Internal Wall Panel 42, may feature Strategically Profiled Edges 50, such that when an Individual Modular Internal Wall Panel 42, is positioned next to an adjoining Individual Modular Internal Wall Panel 42, the Steel Wall Studs 22, positioned at the junctures of the Internal Lining Boards 47, may be held captive, and therefore may be positioned without the use of alternative fastening means.


With reference to the drawings, in particular to FIG. 33, FIG. 34 and FIG. 35, in some embodiments, the Upper Internal Wall Bearing Plate 43, features Strategically Positioned Filler Holes 51, that allow the voids in-between adjoining Individual Modular Internal Wall Panels to be filled with PU foam 52, allowing the Upper Internal Wall Bearing Plate 43, the Lower Internal Wall Bearing Plate 44, and the two adjoining Individual Modular Internal Wall Panels 42, to become structurally adjoined by the PU Foam 52, once the PU foam 52, has been allowed to cure.


With reference to the drawings, in particular to FIG. 28, and FIG. 33, embodiments of the Internal Wall Panel 3, may feature, the Steel Wall Studs 22, strategically positioned such that when fastened to both adjoining Individual Modular External Wall Panels 42, a smooth transition may be created between each face of the adjoining Internal Lining Boards 47, on both sides of the wall, such that when Internal Wall Lining Layers 41 are applied, a smooth and flat surface may be maintained.


With reference to the drawings, in particular to FIG. 27, FIG. 28, FIG. 34, and FIG. 35, in some embodiments, the Steel Wall Studs 22, may be strategically positioned in such a manner that the intersection between adjoining Internal Lining Boards 47, between two adjoining Individual Modular External Wall Panels 42, becomes enclosed on both sides of the wall, such that when the Upper Internal Wall Bearing Plate 43 and the Lower Internal Wall Bearing Plate 44, may be fitted, the void created at the junction of two adjoining Individual Modular External Wall Panels 42, may be able to be filled with liquid PU Foam 52 while being contained within this void, such that when the PU Foam 52, is allowed to cure, a bonded connection may be formed between the adjoining Individual Modular External Wall Panels 42, the Upper Internal Wall Bearing Plates 43, the Lower Internal Wall Bearing Plates 44, the Steel Wall Studs 22, and the Internal Vertical Connection Rods 45, such that the Internal Wall Panel 3, may be fastened together to create an Internal Wall Panel 3, up to a desired length.


With reference to the drawings, in particular to FIG. 33, and FIG. 34, embodiments of the Internal Wall Panel 3, the PU Foam 24, may be strategically positioned in order to provide additional structural integrity to the Steel Wall Studs 22, by interlocking with the Steel Wall Studs 22, and preventing buckling under extreme load or fire exposure conditions.


With reference to the drawings, in particular to FIG. 35, FIG. 36, and FIG. 2, in some embodiments of the Internal Wall Panel 3, may include the Internal Vertical Connection Rods 45, which may be strategically positioned within the Internal Wall Panel 3, and may protrude vertically above and below the Upper Internal Wall Bearing Plate 43 and the Lower Internal Wall Bearing Plate 44, such that a connection may be made above and below the Internal Wall Panel 3, to the adjoining Floor Panels 4, Mid Floor Panels 5, and Roof Panels 6, and the protruding sections of the Internal Vertical Connection Rods 45, may act as pinned connections, which may be accepted into Strategically Placed Holes 53, in corresponding positions situated in the adjoining Floor Panels 4, Mid Floor Panels 5, and Roof Panels 6, such that the pinned connections above and below the Internal Wall Panel 3, in combination with fully restrained connections at each end of the adjoining Floor Panels 4, Mid Floor Panels 5, and Roof Panels 6, the Internal Wall Panels 3, may be placed and restrained within the finished structure, without intrusive fastening methods that would otherwise be required to fasten the Internal Wall Panel 3, to the adjoining Floor Panels 4, Mid Floor Panels 5, and Roof Panels 6.


With reference to the drawings, in particular to FIG. 27, and FIG. 28, embodiments may also include the Internal Wall Lining Layers 41, may be fixed to the both faces of an Internal Wall Panel 3, by means of adhesive or other fastening techniques, such that combined with the Steel Wall Studs 22, maintaining a flat transition between adjoining Individual Modular External Wall Panels 42, Internal Wall Lining layers 41, may be applied to the entire finished Internal Wall Panel 3 on either side, providing a flat and smooth internal lining surface for both sides of the Internal Wall Panel 3, eliminating the need for further traditional surface finishing processes including but not limited to: DryWall application, DryWall joint compound application, Drywall skimming, surface priming and painting.


With reference to the drawings, in particular to FIG. 24, FIG. 25 and FIG. 26, the Internal Wall Panel 3, may include the modification of Male Joining Mechanisms 39, or Female Joining Mechanisms 40, where the Male Joining Mechanism 39 may include of a round disc attached to the end of a supporting rod, and the Female Joining Mechanism 40 may include of a keyhole shaped slot, such that a the Male Joining Mechanisms 39 of one Internal Wall Panel 3, may be inserted into the larger diameter holes of the key shaped slots featured in the Female Joining Mechanisms 40, such that when the Internal Wall Panel 3 featuring the Male Joining Mechanisms 39, may be lowered into its final position, the Male Joining Mechanisms 39, may become captive within the Female Joining Mechanisms 40, such that structural attachment may be formed between Internal Wall Panels 3, and other Internal Wall Panels 3, or between Internal Wall Panels 3, and External Wall Panels 2, while all finished surfaces may remain in-tact during final assembly.


With reference to the drawings, in particular to FIG. 2, and FIG. 37 and FIG. 38, embodiments of the present disclosure may include Floor Panels 4, in some embodiments, the Floor Panels 4, may be further comprised of multiple layers described herein, which may be attached by adhesive, or by other means, to one another, the layers and components described herein include, a substantially rectangular, elongated, strategically profiled expanded EPS Foam Core 54, sandwiched between a Metal Lower Layer 55, and an Upper Structural Floor Board Layer 56, with Floor Panel End Caps 57, positioned at each end, and Male Steel Floor Joists 58, and Female Steel Floor Joists 59, which may be attached to the EPS Foam Core 54, by means of a PU Foam Body 60, running the length of the Floor Panel 4, on either side, in some embodiments, a Finished Flooring Layer 61, may also be present on top of the Upper Structural Floor Board Layer 56, such that a Finished Flooring Layer 60, may be present before final assembly of the building takes place.


With reference to the drawings, in particular to FIG. 39, FIG. 42 and FIG. 43, in some embodiments, the EPS Foam Core features Strategically Profiled Edges 62, such that upon assembly, the Male Steel Floor Joist 58, and Female Steel Floor Joist 59, may form a snug fit with the EPS Foam Core 54, and the Male Steel Floor Joist 58, and Female Steel Floor Joist 59, may be correctly located against the EPS Foam Core 54, during assembly, and a seal may be formed between the Male Steel Floor Joist 58, Female Steel Floor Joist 59, and the edge of the EPS Foam Core 54.


With reference to the drawings, in particular to FIG. 38, FIG. 39, FIG. 42 and FIG. 43, the EPS Foam Core 54, features a smaller width than the Structural Floor-Board Layer 56, and the Metal Lower Layer 55, creating a Void 63, in-between both the adjoining Male Steel Floor Joist 58, and adjoining Female Steel Floor Joist 59 may be formed.


With reference to the drawings, in particular to FIG. 38, and FIG. 43, some embodiments may be positioned such that the Void 63, in-between the EPS foam Core 54, and both the Male Steel Floor Joist 58, and the Female Steel Floor Joist 59, may be filled with liquid PU Foam 60, such that when the PU Foam 60, is allowed to cure, a bond between the EPS foam Core 54, and both the Male Steel Floor Joist 58, and the Female Steel Floor Joist 59 may be formed.


With reference to the drawings, in particular to FIG. 38 and FIG. 43, in some embodiments, the bond between the EPS foam Core 54, and both the Male Steel Floor Joist 58, and the Female Steel Floor Joist 59 may be formed, may provide structural reinforcement for both the Male Steel Floor Joist 58, and the Female Steel Floor Joist 59 in terms of lateral support, which may further enhance the structural integrity of the Floor Panel 4, and may allow for the spanning of the Floor Panel 4, over greater distances between supports.


With reference to the drawings, in particular to FIG. 38 and FIG. 44, the embodiments of both the Male Steel Floor Joist 58, and the Female Steel Floor Joist 59, may feature strategically positioned Filler Holes 64, which may be positioned along the lengths of both the Male Steel Floor Joist 58, and the Female Steel Floor Joist 59, such that when the Floor Panel End Caps 57, may be fitted to either end of the Floor Panel 4, the Void 63, between the EPS foam Core 54, and both the Male Steel Floor Joist 58, and the Female Steel Floor Joist 59, may become sealed, such that it may be filled with liquid PU Foam 60, such that once the PU Foam 60, is allowed to cure and become solid, a connection between the EPS foam Core 54, and both the Male Steel Floor Joist 58, and the Female Steel Floor Joist 59, may be formed.


With reference to the drawings, in particular to FIG. 38, FIG. 45, and FIG. 46, the EPS Foam Core 54, sandwiched between a Metal Lower Layer 55, and an Upper Structural Floor Board Layer 56, may provide structural floor layer, where the layers are joined together using adhesive, such that when the layers become joined, they may support load, in particular, bending load, between the distance from the Male Steel Floor Joist 58, across to the Female Steel Floor Joist 59 located on the other side of the Floor Panel 4, such that the Male Steel Floor Joist 58, and the Female Steel Floor Joist 59, may support load across the span running lengthwise to the Floor Panel, and the Upper Structural Floor Board Layer 56, attached to the EPS Foam Core 54 and the Metal Lower Layer 55, may support load across the span running widthwise to the Floor Panel, in between the Male Steel Floor Joist 58, and the Female Steel Floor Joist 59.


With reference to the drawings, in particular to FIG. 45, embodiments of the Metal Lower Layer 55, that may be comprised of a flat metal sheet, running the length of the Floor Panel 4, that may form a structural lower layer.


With reference to the drawings, in particular to FIG. 46, embodiments of the Upper Structural Floor Board Layer 56, may be further comprised of multiple flat boards arranged down the length of the Floor Panel 4, that may form a structural upper layer for the panel, and therefore may provide a load bearing surface, on which a floor may be situated.


With reference to the drawings, in particular to FIG. 38, FIG. 40, FIG. 41, FIG. 47, FIG. 48, FIG. 49, and FIG. 50, in some embodiments, Male Inter-floor Locking Mechanisms 65, or Female Inter-floor Locking Mechanisms 66, may be fitted, such that connections may be formed between completed Floor Panels 4, where the Male Inter-floor Locking mechanism 65, may include of a round disc attached to the end of a supporting rod, and the Female Inter-floor Locking Mechanism 66, may include of a keyhole shaped slot, such that the Male Inter-floor Locking Mechanism 65, may be inserted into the larger hole of the key shaped slot of the Female Inter-floor Locking Mechanism 66, as described in FIG. 48, such that when the panel featuring the Male Inter-floor Locking mechanisms 65, may be lowered into its final position, such that the supporting rod of the Male Inter-floor Locking Mechanisms 65, slides down the key shaped slot of the Female Inter-floor Locking Mechanisms 66, a connection may be formed, as described in FIG. 49, connecting one Floor Panel 4 to another adjoining Floor Panel 4.


With reference to the drawings, in particular to FIG. 47, FIG. 49 and FIG. 50, embodiments of the Female Inter-floor Locking Mechanism 66, may include Angular Tabs 67, such that upon the Male Inter-floor Locking Mechanism 65, being inserted into the larger hole of the key shaped slot of the Female Inter-floor Locking Mechanism 66 and slid down the key shaped slot of the Female Inter-floor Locking Mechanism 66, as outlined in FIG. 49, the Angular Tabs 67, may make contact with the Round Disc of the Male Inter-floor Locking mechanism 65, such that the Male Inter-floor Locking mechanism 65, and hence Male Steel Floor Joist 58, and hence the Floor Panel 4, that it may be attached to, may be pulled toward the other Floor Panel 4, featuring the Female Inter-floor Locking Mechanism 66, that the original Floor Panel 4, is attaching to, such that a tight tolerance may be maintained between the adjoining Floor Panels 4, and that some tolerance for error may be maintained in the shape and straightness of the connecting Floor Panels 4.


With reference to the drawings, in particular to FIG. 51, and FIG. 52, in some embodiments, the Mid-Floor Panels 6, feature similar components, features and functions described in points [0162] to [0172] herein, with the only modifications being the order and quantity of the layers, and the addition of a Lower Ceiling Finishing Layer 68, and the removal of the Metal Lower Layer 55, which may be replaced with a Lower Structural Board Layer 69, such that the layers, listed from the top of the panel to the bottom of the panel, may be ordered in the following sequence; Finished Flooring Layer 61, Upper Structural Floor Board Layer 56, EPS Foam Core 54, Lower Structural Board Layer 69, and the Lower Ceiling Finishing Layer 68.


With reference to the drawings, in particular to FIG. 51, and FIG. 52, the EPS Foam Core 54, sandwiched between a Lower Structural Board Layer 69, and an Upper Structural Floor Board Layer 56, may provide structural floor layer, where the layers are joined together using adhesive, such that when the layers become joined, they may support load, in particular, bending load, between the distance from the Male Steel Floor Joist 58, across to the other side of the Mid-floor Panel 5, where the Female Steel Floor Joist 59 is located, such that the Male Steel Floor Joist 58, and the Female Steel Floor Joist 59, may support load across the span running lengthwise to the Mid-floor Panel, and the Upper Structural Floor Board Layer 57, and the Lower Structural Board Layer 69, when attached to the EPS Foam Core 54, may support load across the span running widthwise to the Mid-floor Panel 5, in between the Male Steel Floor Joist 58, and the Female Steel Floor Joist 59.


With reference to the drawings, in particular to FIG. 51, and FIG. 52, the embodiments of the Mid-Floor Panel, may include the addition of a Ceiling Finishing Layer 68, such that the Ceiling Finishing Layer 68, may be fixed to the underside of the Lower Structural Board Layer 69, with the lining material featuring a strategic width and thickness, such that the material width may be equal or greater than the width of the Mid-floor Panel 5, and a thickness that may be sufficient such that it may cover imperfections on the underside of the Lower Structural Board Layer 69, whereby the Ceiling Finishing Layer 68, may be fixed to the entire underside of the Lower Structural Board Layer 69 by means of adhesive or other fastening, providing a flat, smooth and finished ceiling surface, situated on the underside of the Mid-floor Panel 5, such that a ceiling may be created by the Mid-floor Panel 5, in the room of the building situated below the Mid-floor Panel 5, eliminating the need for further traditional surface finishing processes including but not limited to; DryWall application, DryWall joint compound application, Drywall skimming, surface priming and painting.


With reference to the drawings, in particular to FIG. 53, and FIG. 54, in some embodiments, the Roof Panels 6, feature similar components, features and functions described in points [0162] to [0172] herein, with the only modifications being the order and quantity of the layers, where the Metal Lower Layer 55, may be replaced by a Lower Structural Board Layer 69, and the Upper Structural Floor Board Layer 56, may be replaced by an Upper Structural Metal Layer 70, and there may be an addition of a Lower Ceiling Finishing Layer 68, such that the layers, listed from the top of the panel to the bottom of the panel, may be ordered in the following sequence; Upper Structural Metal Layer 70, EPS Foam Core 54, Lower Structural Board Layer 69, and the Lower Ceiling Finishing Layer 68.


With reference to the drawings, in particular to FIG. 54, and FIG. 55, the EPS Foam Core 54, sandwiched between a Lower Structural Board Layer 69, and an Upper Structural Metal Layer 70, may provide a structural Roof layer, where the layers are joined together using adhesive, such that when the layers become joined, they may support load, in particular, bending load, between the distance from the Male Steel Floor Joist 58, across to the other side of the Roof Panel 6, where the Female Steel Floor Joist 59 is located, such that the Male Steel Floor Joist 58, and the Female Steel Floor Joist 59, may support load across the span running lengthwise to the Roof Panel 6, and the Upper Structural Metal Layer 70, EPS Foam Core 54, Lower Structural Board Layer 69, when attached to the EPS Foam Core 54, may support load across the span running widthwise to the Roof Panel, in between the Male Steel Floor Joist 58, and the Female Steel Floor Joist 59.


With reference to the drawings, in particular to FIG. 54, and FIG. 55, the embodiments of the Roof Panel, may include the addition of a Ceiling Finishing Layer 68, such that the Ceiling Finishing Layer 68, may be fixed to the underside of the Lower Structural Board Layer 69, with the lining material featuring a strategic width and thickness, such that the material width may be equal or greater than the width of the Roof Panel 6, and a thickness that may be sufficient such that it may cover imperfections on the underside of the Lower Structural Board Layer 69, whereby the Ceiling Finishing Layer 68, may be fixed to the entire underside of the Lower Structural Board Layer 69 by means of adhesive or other fastening, providing a flat, smooth and finished ceiling surface, situated on the underside of the Roof Panel 6, such that a ceiling may be created by the Roof Panel 6, in the room of the building situated below the Roof Panel 6, eliminating the need for further traditional surface finishing processes including but not limited to; DryWall application, DryWall joint compound application, Drywall skimming, surface priming and painting.


With reference to the drawings, in particular to FIG. 56, embodiments of the present disclosure may include Window Panels 7, whereby in some embodiments, the Window Panels 7, may attach to adjoining Exterior Wall Panels 2, and adjoining Floor Panels 4, Mid-floor Panels 5, and Roof Panels 6, such that a window or door, may be present in the finished structure of the Modular Building System 1.


With reference to the drawings, in particular to FIG. 55FIG. 56, FIG. 57, and FIG. 58, in some embodiments, the Window Panel 7, may be comprised of a Structural Metal Frame 71, and a Non-structural Window or Door Component 72, which may be attached together by means of PU foam 74, such that the Structural Metal Frame 71, which may be sized with similar width increments as the Individual Modular External Wall Panels 18, may provide structural support for the Non-structural Window or Door Component 72, and may provide structural integrity of similar or greater capacity as the External Wall Panels 2, described herein, enabling the Window Panel 7, to maintain its own structural integrity, and provide structural support capacity including but not limited to; shear loading, bending loading and vertical support to adjoining Mid-floor Panels 5, and Roof Panels 6, situated above the Window Panel 7, and may provide any other structural functions that the Structural Metal Frame 71, may be able to provide to the structure, eliminating the need for structural considerations that are required for traditional external window and door design.


With reference to the drawings, in particular to FIG. 60, FIG. 61 and FIG. 62, embodiments of the Non-structural Window or Door Components 72, may feature Strategically Shaped Vertical Window Profiles 75, such that the Window Panel 7, may be capable of attaching to adjoining Individual Modular External Wall Panels 18, by means of positioning Weatherproof Connection Mechanisms 19, to connect the external face of the Strategically Shaped Vertical Window Profile 75, to the Metal Siding Layer 27, of the adjoining Individual Modular External Wall Panels 18, such that a continuous weatherproof face may be created between the junctions of the Window Panel 7 and the adjoining Individual Modular External Wall Panels 18, and hence the entire length of the External Wall Panel 2.


With reference to the drawings, in particular to FIG. 62, in some embodiments, the Structural Metal Frame 71, and the Non-structural Window or Door Component 72, may be attached to one another by means of filling the Void 73, situated between the Structural Metal Frame 71, and the Non-structural Window or Door Component 72 with liquid PU foam 74, such that when the PU Foam 74 is allowed to cure, a connection may be formed between the Structural Metal Frame 71, and the Non-structural Window or Door Component 72.


With reference to the drawings, in particular to FIG. 62, in some embodiments, the Window Panel 7, and the adjoining Individual Modular External Wall Panels 18, may be attached to one another by means of filling the Void 73, situated between the Window Panel 7, and the adjoining Individual Modular External Wall Panels 18, which is also the same Void 73, that is situated between the Structural Metal Frame 71, and the non-opening portion of the frame of Non-structural Window or Door Component 72, such that when the PU Foam 74, is allowed to cure, a connection may be formed between the Window Panel 7, and the adjoining Individual Modular External Wall Panels 18, integrating the Window Panel 7 into the assembly of the External Wall Panel 2, in which the Window Panel 7, may be featured.


With reference to the drawings, in particular to FIG. 61 and FIG. 62, in some embodiments, the Strategically Shaped Vertical Window Profiles 75, may feature a C Shaped Groove 76, on the internal facing side of the profile, such that the Internal Lining Board 28, of the adjoining Individual Modular External Wall Panels 18, can slide into the C Shaped Groove 76, allowing for a finished edge at this junction, without requiring the addition of trim, the C shaped groove 76 may also feature an elongated edge on the inner side of the profile, such that screws, glue or PU foam 74, may be utilized to fasten the Internal Lining Board 28, to the Strategically Shaped Vertical Window Profiles 75.


With reference to the drawings, in particular to FIG. 62. embodiments of the Non-structural Window or Door Component 72, may feature strategically shaped Lower Horizontal Profiles 77, which may feature a similar channel as described within the description of the Lower Wall Bearing Plates 21, of the External Wall Panel 2, such that the strategically shaped Lower Horizontal Profile 77, may accept the Lower Exterior Wall Flashing 13, described in the External Wall Panel 2, by which the strategically shaped Lower Horizontal Profile 77, may also feature strategically shaped ends, capable of interlocking with the Weatherproof Connection Mechanisms 19, of the adjoining Individual Modular External Wall Panels 18, such that a continuous weathertight connection may be formed at the lower edge of the intersection in between the Individual Modular External Wall Panel 18 and the Non-structural Window or Door Component 72.


With reference to the drawings, in particular to FIG. 63, FIG. 64 and FIG. 65, embodiments of the Window Panel 7, and the Structural Metal Frame 71, may include the Male Inter-floor Locking mechanisms 65, and or the Female Inter-floor Locking Mechanisms 66, as featured in the description of the Floor Panel 4, Mid-floor Panel 5, and Roof Panels 6, such that the Structural Metal Frame 71 of the Window Panel 7, may attach to adjoining Floor Panels 4, Mid-floors Panel 5, and Roof Panels 6.


With reference to the drawings, in particular to FIG. 63, FIG. 64 and FIG. 65, embodiments of the Structural Metal Frame 71, may include strategically placed holes such that the Vertical Connection Rods 23, may fasten the Structural Metal Frame 71 to adjoining External Wall Panels 2


With reference to the drawings, in particular to FIG. 65, embodiments of the Lower Structural Embodiment 78, of the Structural Metal Frame 71, may be strategically shaped and positioned in relation to the adjoining Floor Panel 4, or Mid-floor Panel 5, such that the Lower Embodiment 79, of the Non-structural Window or Door Component 70, may be situated below the Finished Internal Floor Level 80, of the adjoining panel, such that door sliding tracks, door jambs and window jambs may be recessed below the Finished Internal Floor Level 80, of the adjoined Floor Panel 4, or Mid-floor Panel 5, such that a similar finished height and even transition may be maintained between finished floor levels inside and outside of the structure.


With reference to the drawings, in particular to FIG. 66 and FIG. 67, embodiments described herein may include the Structural Floor Joining Brackets 9, which may be further comprised of embodiments that may include a Rectangular Hollow Section 81 and a Sliding Locking Plate 82, such that the Sliding Locking Plate 82, which may be positioned within the Rectangular Hollow Section 81.


With reference to the drawings, in particular to FIG. 2, and FIG. 67, and FIG. 71, the Structural Floor Joining Bracket 9, may be located beneath an Internal Wall Panel 3, and in between adjoining Floor Panels 4, or Mid-floor Panels 5, or Roof Panels 6, and may also be positioned above another Internal Wall Panel 3, such that the Structural Floor Joining Bracket 9, may form a connection between each of the adjoining panels, in a manner in which no intrusive fastening methods may be required, such that finishing materials applied to the various panels may be maintained during the final assembly of the structure.


With reference to the drawings, in particular to FIG. 2, FIG. 68, FIG. 69, FIG. 70, and FIG. 71, embodiments of the Rectangular Hollow Section 81 may feature Strategically Placed Holes 83, positioned to align with the Internal Vertical Connection Rods 45, of the Internal Wall Panel 3, situated above Structural Floor Joining Bracket 9, allowing the Internal Vertical Connection Rods 45, such that they may enter into the Strategically Placed Holes 83 of the Rectangular Hollow Section 81, and also through the larger section of the Key Shaped Slots 84, of the Sliding Locking Plate 82, such that the Internal Wall Panel 3, may rest on the Structural Floor Joining Bracket 9.


With reference to the drawings, in particular to FIG. 70, and FIG. 71, the Rectangular Hollow Section 81 and a Sliding Locking Plate 82, may feature Access Points 85, such that bolts, screws, or other fasteners may be utilized in order to fasten the Structural Floor Joining Bracket 9, to the adjoining Floor Panels 4, or Mid-floor Panels 5, and the Internal Wall Panel 3, situated below the Structural Floor Joining Brackets 9, and that embodiments of the Rectangular Hollow Section 81 and a Sliding Locking Plate 82, may feature Precut Holes 86, which may assist with the attachment of the fasteners described herein.


With reference to the drawings, in particular to FIG. 71, FIG. 72, FIG. 73, FIG. 74, and FIG. 77, embodiments of the Internal Vertical Connection Rod 45, of the Internal Wall Panel 3, may feature Disc Shaped Ends 87, such that the Disc Shaped Ends 87, may be smaller than the larger portion of the Key Shaped Slot 84 in the Sliding Locking Plate 82, but smaller than the smaller portion of the Key Shaped Slot 84 in the Sliding Locking Plate 82, such that if the Sliding Locking Plate 82, is moved, from one end, or otherwise, from the Open Position 88, to the Closed Position 89, the Disc Shaped Ends 87, of the Internal Vertical Connection Rod 45 may be come captive, and hence a connection may be formed between the Internal Wall Panel 3, and the Structural Floor Joining Bracket 9, and hence the adjoining Floor Panels 4, or Mid-floor Panels 5, and the Internal Wall Panel 3, situated below the Structural Floor Joining Bracket 9, such that a structural connection may be formed between the panels described herein, as described in FIG. 77, without the use of invasive fastening methods, and hence keeping the finished surfaces of the various panels intact, upon final assembly of the building.


With reference to the drawings, in particular to FIG. 74, FIG. 75, FIG. 76, and FIG. 77, embodiments of the Key Shaped Slots 84, of the Sliding Locking Plate 82, may feature Tapered Inward Sloping Edges 90, such that if the Sliding Locking Plate 82, is moved, from the Open Position 88, to the Closed Position 89, the Disc Shaped Ends 87, of the Internal Vertical Connection Rod 45 may be pulled towards the Structural Floor Joining Bracket 9, causing the Internal Wall Panel 3, to be pulled down firmly only the Structural Floor Joining Bracket 9, such that a structural connection may be formed, which may also allow for an allowable manufacturing tolerance to be maintained in the construction process of the Internal Wall Panels 3, and the Structural Floor Joining Bracket 9, such that if the Disc Shaped Ends 87, of the Internal Vertical Connection Rods 45, may not be perfectly vertically aligned with the Key Shaped Slots 84, of the Sliding Locking Plate 82, a connection may still be achieved, due to the Tapered Inward Sloping Edges 90, of the Sliding Locking Plate 82.


With reference to the drawings, in particular to FIG. 2, FIG. 78, and FIG. 79, embodiments described herein may include External Wall Connection Brackets 10, embodiments of the External Wall Connection Brackets 10, may be comprised of a C shaped member, which may be situated and connected along the outside edge of a Floor Panel 4, a Mid-floor Panel 5, or a Roof Panel 6, such that an External Wall Panel 2, may be situated and connected above or below the mentioned Floor Panel 4, a Mid-floor Panel 5, or a Roof Panel 6, such that a structural connection may be formed between the External Wall Connection Brackets 10 and the adjoining Floor Panel 4, a Mid-floor Panel 5, or a Roof Panel 6, and the External Wall Panels 2 that may be situated above or below the External Wall Connection Brackets 10, and hence between all of the adjoining panels.


With reference to the drawings, in particular to FIG. 78, and FIG. 79, embodiments of the External Wall Connection Brackets 10 may feature Male Inter-floor Locking mechanisms 65, and or the Female Inter-floor Locking Mechanisms 66, such that connections may be made between the External Wall Connection Bracket 10, and the adjoining Floor Panel 4, a Mid-floor Panel 5, or a Roof Panel 6, and the External Wall Connection Brackets 10, may also feature holes such that connection may be made using the Vertical Connection Rods 23, of the External Wall Panels 2, as described in FIG. 79, such that load may be transferred through the panels, and the External Wall Connection Brackets 10, and may be distributed into the foundation of the building.


With reference to the drawings, in particular to FIG. 80, the embodiments of the External Wall Connection Brackets 10, External Wall Connection Brackets 10, and the positioning of such embodiments, may allow for External Wall Panels 2, to be situated outside the floor structure, this may provide the benefit of maintaining full panel widths within the interior of the structure, such that partial width panels may not be required to be used, as they would need to be if the External Wall Panels 2, were situated on top of the flooring structure, this also may provide the benefit of the External Wall Panels 2, and also Window Panels 7, to be situated below the finished floor height of the structure, which may provide the benefit of enhanced protection against water ingress at the junction in between the Exterior Wall Panels 2, and the adjoining Floor Panel 4, or Mid-floor Panel 5 structure.


With reference to the drawings, in particular to FIG. 81, embodiments described herein may include Exterior Wall Butt Joining Brackets 11, which may be situated between External Wall Panels 2, that may adjoin end to end, where a joint may be required within an external wall, to allow for transportation, or where an Internal Wall Panel 3, may be required in order to support an end of a Floor Panel 4, or Mid-floor Panel 5, or Roof Panel 6.


With reference to the drawings, in particular to FIG. 81, FIG. 82, FIG. 83, and FIG. 84, the Wall Butt Joining Bracket 11, may be further comprised of a Structural U Shaped Bracket 91, and a Straight External Wall Panel Siding Joiner 92, whereby the Structural U Shaped Bracket 91, may be attached by screws, bolts, or by other means, to the adjoining External Wall Panels 2, and the adjoining Internal Wall Panel 3, such that a structural connection may be formed in between the External Wall Panels 2, and the Internal Wall Panel 3 mentioned herein, and that the Straight External Wall Panel Siding Joiner 92, may interlock with the Metal Siding Layers 27, of the Individual Modular External Wall Panels 18, of the adjoining External Wall Panels 2. Such that a weather-proof layer may be formed in between the adjoining External Wall Panels 2.


With reference to the drawings, in particular to FIG. 3, FIG. 85 and FIG. 89, embodiments described herein may include Exterior Wall Corner Brackets 12, which may be situated between External Wall Panels 2, that may adjoin at an external corner of the structure, where a corner joint may be required.


With reference to the drawings, in particular to FIG. 85, FIG. 86, FIG. 87, and FIG. 88, the Exterior Wall Corner Brackets 12, may be further comprised of a Structural L Shaped Bracket 93, and a Boxed Corner Siding Joiner 94, whereby the Structural L Shaped Bracket 93, may be attached by screws, bolts, or by other means, to the adjoining External Wall Panels 2, which may be situated at right angles to one another, such that a structural connection may be formed in between the mentioned External Wall Panels 2, and that the Boxed Corner Siding Joiner 94, may be strategically shaped such that it may interlock with the Metal Siding Layers 27, of the Individual Modular External Wall Panels 18, of the External Wall Panels 2, that may be adjoining at right angles, and such that a weatherproof layer may be formed at the corner of the building.


With reference to the drawings, in particular to FIG. 90, and FIG. 91, embodiments described herein may include a Foundation System 15, which may provide a foundation for the Modular Building System 1, to rest on, and hence attach to the ground, which may feature components described herein that may allow for rapid construction of a foundation, which may dramatically decrease final assembly time of the Modular Building System 1.


With reference to the drawings, in particular to FIG. 90, FIG. 91, FIG. 92, FIG. 94, FIG. 95 and FIG. 96, embodiments of the Foundation System 15, may be further comprised of embodiments described herein which may include Helical Screw Pile Foundations 95, or any other type of foundation that may be required due to the ground substrate, Flexible Foundation Mounting Brackets 96, and Structural Floor Bearers 97.


With reference to the drawings, in particular to FIG. 90, FIG. 91, FIG. 92, and FIG. 96, embodiments of the Helical Screw Pile 95, where applicable dependent on soil substrate may be utilized, such that they may be driven into the ground where the structure is to be assembled, which may form an attachment to the ground for the Foundation System 15, which may include the benefits of being removable when required, and may allow for rapid installation of the Helical Screw Pile Foundations 95, where applicable.


With reference to the drawings, in particular to FIG. 96, and FIG. 97, embodiments of the Helical Screw Piles 95 may feature Slotted Mounting Plates 98, such that the Flexible Foundation Mounting Brackets 96, may be mounted on top of the Slotted Mounting Plates 98, allowing for lateral fitment tolerance to be maintained, as the Flexible Foundation Mounting Brackets 96, may be bolted to the Slotted Mounting Plates 98, of the Helical Screw Piles 95 in various positions along the Slots 99 of the Slotted Mounting Plates 98.


With reference to the drawings, in particular to FIG. 94, FIG. 95 and FIG. 97, embodiments of the Flexible Foundation Mounting Brackets 96, may feature a Flexible Bearing Pad 100, which may be positioned on top of the Mounting Plates 98, of the Helical Screw Piles 95, whereby the Flexible Foundation Mounting Bracket 96 may also feature an Upper Bracket Plate 10, situated on top of the Flexible Bearing Pad 100, whereby the Upper Bracket Plate 102, may be attached to the Mounting Plate 98, of the Helical Screw Pile 96, by Mounting Bolts 101, such that the bolts may be tightened to various lengths, such that the Flexible Bearing Pad 100, may compress at an angle to the Mounting Plates 98, of the Helical Screw Piles 95, such that Upper Bracket Plate 102, may have its position, including angle and height, may be adjusted with respect to the Mounting Plate 98, of the Helical Screw Pile 95, such that a level mounting surface may be achieved, of a desired finished height, allowing for some error tolerance in the angle and finished height of the Mounting Plates 98, of the Helical Screw Piles 95, due to the fact that Helical Screw Pile 96 installation may have an inherent degree of inaccuracy due to various factors.


With reference to the drawings, in particular to FIG. 94, FIG. 95, FIG. 96, and FIG. 97, embodiments the Upper Bracket Plates 102, situated on top of the Flexible Rubber Bearing Pad 100, of the Flexible Foundation Mounting Brackets 96, may feature an attached Threaded Rod and Fastening Nut 104 orientated vertically, such that when the Structural Floor Bearers 97, may rest on top of the Flexible Foundation Mounting Brackets 96, the Threaded Rod and Fastening Nut 104 may protrude through a strategically shaped and positioned Bearer Slot 103, located within the Structural Floor Bearers 97, such that a Threaded Rod and Fastening Nut 104 of the Flexible Foundation Mounting Bracket 96, may be fastened, such that a structural connection may be formed between the Flexible Foundation Mounting Bracket 96, and the Structural Floor Bearer 97.


With reference to the drawings, in particular to FIG. 91, FIG. 92, and FIG. 94, embodiments the Structural Floor Bearers 97, may be formed with similar shape, form and function to that of the Structural Floor Joining Brackets 9 described herein, with the addition of a strategically shaped and positioned Bearer Slot 103, in the bottom profile of the Rectangular Hollow Section 81, of the Structural Floor Joining Brackets 9, such that the Threaded Rod and Fastening Nut of the Flexible Foundation Mounting Bracket 96, may attach at various positions along the Bearer Slot 104, such that combined with the Slotted Mounting Plates 98, of the Helical Screw Piles 95, and the finished height and angle adjustment allowed for in the Flexible Foundation Mounting Brackets 96, the structural connection between the Structural Floor Bearers 97, and the Helical Screw Piles 95, may be made with the ability to be adjusted into various positions, allowing for a large degree of dimensional installation error that may be present in the installed Helical Screw Piles 95, such that the large dimensional error tolerance that may be inherent with Helical Screw Pile 95 installation, may be accepted by the much smaller error tolerance of the Modular Building System 1 described herein.


With reference to the drawings, in particular to FIG. 98, and FIG. 99, embodiments described herein may include a Roofing System 8, which may provide a sloped roofing structure, which may be situated on top of the Roof Panels 6, of the assembled structure, whereby the Roofing System 8, may be assembled such that it may create a roofing slope of any required angle, and an Eave 106, at the lower edge of the roof, of a desired length, such that roofing slope and eave requirements for buildings within various geographical areas, may comply with multiple local construction standards and requirements for a specific area.


With reference to the drawings, in particular to FIG. 98 and FIG. 99 embodiments of the Roofing System 8, may be further comprised of embodiments which may form the structural and weatherproof components of the Roofing System 8, embodiments described herein may include the Roof Panel 6, a Roof Anchoring Bracket 107, a Foldable Roof Truss 108, a Snap Together Roofing Purlin 109, and a Snap On Metal Roofing Layer 110.


With reference to the drawings, in particular to FIG. 100, the Roof Anchoring Bracket 106, may be comprised of a long C shaped bracket, which may attach to the Roof Panels 6, of the structure, by means of Roof Anchor Clips 111, which may be situated on the Upper Structural Metal Layer 68, of the Roof Panels 6, such that strategically placed Anchor Cut-outs 112, located on the lower portion of the Roof Anchoring Bracket 107, may be pressed over the Roof Anchor Clips 111, which may be situated on the Upper Structural Metal Layer 70, of the Roof Panels 6, such that an attachment may be made between the Roof Anchoring Bracket 107, and the Roof Panel 6, by means of a clip in style mechanism, whereby both the Roof Anchor Clips 111, and the strategically placed Anchor Cut-outs 112, may be manufactured into the Upper Structural Metal Layer 70, of the Roof Panels 6, and the Roof Anchoring Bracket 107, by means of metal stamping, or metal pressing, or by other means, during a roll forming manufacturing process, or by other means of manufacturing, such that components may be manufactured economically, at scale.


With reference to the drawings, in particular to FIG. 101, FIG. 102, and FIG. 103, the Foldable Roof Truss 108, may be comprised of a Sloping Member 113, and Folding Support Members 114, which may be attached to the Sloping Member 113, by means of a Pinned Connection 115, such that, the Foldable Roof Truss 108, may be folded as described in FIG. 102, which may enable more efficient transportation, and may be unfolded upon final assembly of the Roofing System 8, creating a sloping profile for which a roof may be formed upon assembly on-site.


With reference to the drawings, in particular to FIG. 101 and FIG. 104, embodiments of the Folding Support Members 114, of the Foldable Roof Truss 108, may include Truss Connection Tabs 116, which may locate within strategically placed Truss Connection Cut-outs 117, such that such that an attachment may be made between the Foldable Roof Truss 108, Roof Anchoring Bracket 107, by means of a clip in style mechanism, whereby both the Truss Connection Tabs 116, and the Truss Connection Cut-outs 117, may be manufactured by means of metal stamping, or metal pressing, or by other means, during a roll forming manufacturing process, or by other means of manufacturing, such that components may be manufactured economically at scale.


With reference to the drawings, in particular to FIG. 101, embodiments of the Foldable Roof Truss 108, may include Purlin Connection Tabs 118, shaped such that they may accept the lower edges of the Snap Together Roofing Purlin 109, and a connection may be formed between the Foldable Roof Truss 108, and the Snap Together Roofing Purlin 109, by means of a clip in style mechanism, whereby both the Purlin Connection Tabs 118, and the Snap Together Roofing Purlins 108, may be manufactured by means of metal stamping, or metal pressing, or by other means, during a roll forming manufacturing process, or by other means of manufacturing, such that components may be manufactured economically at scale.


With reference to the drawings, in particular to FIG. 105, FIG. 106, FIG. 107, FIG. 108, FIG. 109, and FIG. 110, embodiments of the Snap Together Roofing Purlin 109, may include Snap-on Roof Layer Connection Hooks 119, such that the Snap On Metal Roofing Layer 110, may be attached to the Snap Together Roofing Purlins 109, by means of first positioning the Male Profile 120, of the Snap On Metal Roofing Layer 110, underneath the Snap-on Roof Layer Connection Hooks 119, by first positioning the Snap On Metal Roofing Layer 110, at an angle to the Snap Together Roofing Purlins 109, and then laying the Snap On Metal Roofing Layer 110, flat onto the Snap Together Roofing Purlins 109, such that the Male Profile 120, of the Snap On Metal Roofing Layer 110, may become captive underneath the Snap-on Roof Layer Connection Hooks 119 of the Snap Together Roofing Purlins 109, which may anchor that side of the Snap On Metal Roofing Layer 110 to the Snap Together Roofing Purlins 109, and as the Snap On Metal Roofing Layer 110, may be laid flat onto the Snap Together Roofing Purlins 109, the Female Hook 121, of the Snap On Metal Roofing Layer 110 may by clip together style connection, attach over the adjoining Snap-on Roof Layer Connection Hook 119 of the Snap Together Roofing Purlins 109, as well as any Male Profile 120, of an adjoining Snap On Metal Roofing Layer 110, such that both the Female Hook 121, of the Snap On Metal Roofing Layer 110 and the Male Profile 120, of an adjoining Snap On Metal Roofing Layer 110, may become captive to the Snap-on Roof Layer Connection Hooks 119 of the Snap Together Roofing Purlins 109, and hence a connection may be made between the Snap On Metal Roofing Layer 110, and the Snap Together Roofing Purlins 109, and subsequently the entire Roofing System 8, such that when applying Snap On Metal Roofing Layers 110, in the direction from the Male Profile 120, to the Female Hook 121, of the Snap On Metal Roofing Layers 110, a continuous finished roof layer, may be formed as outlined in FIG. 110.


With reference to the drawings, in particular to FIG. 105, FIG. 106, FIG. 107, FIG. 108, FIG. 109, and FIG. 110, embodiments of the Snap-on Roof Layer Connection Hooks 119 of the Snap Together Roofing Purlins 109, and the Male Profile 120, and the Female Hook 121, of the Snap On Metal Roofing Layers 110 may be manufactured by means of metal stamping, or metal pressing, or by other means, during a roll forming manufacturing process, or by other means of manufacturing, such that components may be manufactured economically at scale.


With reference to the drawings, in particular to FIG. 111, and FIG. 122, embodiments described herein may include a Decorative Siding System 17, such that various decorative siding layers may be added over the top of the External Wall Panels 2, which may comprise of Stone, Wood, Steel, Aluminum, or other siding materials, such that various aesthetic appearances of the External Wall Panels 2 may be achieved.


With reference to the drawings, in particular to FIG. 111, FIG. 112, FIG. 114, and FIG. 118, embodiments of the Decorative Siding System 17, may be further comprised of embodiments, which may form the clip together style attachment and decorative layer components of the Decorative Siding System 17, such that embodiments described herein may include the Substitute Weather-proof Connection Mechanism 122, a Siding Mounting Batten 123, Decorative Siding Clips 124, and Decorative Siding Panels 125, which may be further comprised of various materials.


With reference to the drawings, in particular to FIG. 111, FIG. 112, FIG. 113, FIG. 114, FIG. 115, and FIG. 117, the Substitute Weather-proof Connection Mechanism 122, may be formed as such that it may replace the Weatherproof Connection Mechanisms 19, during the assembly of the External Wall Panels 2, such that a Mounting Surface 126, may be present for the Siding Mounting Battens 123 to attach, whereby the Mounting Surface 126, of the Substitute Weather-proof Connection Mechanism 122, may feature strategically shaped Batten Mounting Cut-outs 127, and the inside edges of the Siding Mounting Battens 123, may feature strategically shaped and positioned Batten Mounting Tabs 128, such that the Batten Mounting Tabs 128, of the Siding Mounting Battens 123, may fit within the Batten Mounting Cut-outs 127, of the Substitute Weather-proof Connection Mechanisms 122, such that a clip style connection may be formed, and hence the Siding Mounting Battens 123 may be attached to the Substitute Weather-proof Connection Mechanisms 122, and hence the External Wall Panel 2, where the Decorative Siding System 17, is desired to be placed upon the structure.


With reference to the drawings, in particular to FIG. 111, FIG. 112, FIG. 113, FIG. 114, FIG. 115, FIG. 116, FIG. 117, FIG. 118, FIG. 119, FIG. 121, and FIG. 122, the Siding Mounting Battens 123, may feature strategically shaped and positioned Siding Clip Cutouts 129, such that Decorative Siding Clips 124, which may feature strategically shaped and positioned Male Siding Clip Hooks 130, such that when the Decorative Siding Clips 124, may be mounted onto Decorative Siding Panels 125, the Decorative Siding Panels 125, may be mounted onto the Siding Mounting Battens 123, by means of the Male Siding Clip Hooks 130, forming a clip in style connection within the Siding Clip Cutouts 129, of the Siding Mounting Battens 123, and hence the External Wall Panel 2, such that with multiple Decorative Siding Panels 125, the entire External Wall Panel 2, where the Decorative Siding System 17, is desired to be placed upon the structure, may be achieved.


With reference to the drawings, in particular to FIG. 123, the Modular Building System 1, described herein, due to the modular nature of the design, may be used to construct a wide range of building shapes and designs 131, such as the structure pictured in FIG. 123, which may allow the system described to be very versatile, and may provide a large advantage in terms of design flexibility, such that the Modular Building System 1, may fit a wide range of end user requirements, and may cater to various land use shapes and sizes.


The Panelized Modular Building System 1, described herein presents a method of assembling Individual Modular External Wall Panels 18, the process consists of the following steps:

    • a) Metal Siding Layers 27 siding panels may be profiled and prepared by means of roll forming manufacturing or other means.
    • b) Foam Expanded Polystyrene (EPS) Cores 26, may be prepared by means of a CNC controlled hot wire cutting machine, and may be profiled as described in the figures.
    • c) Metal Siding Layers 27, Foam Expanded Polystyrene (EPS) Cores 26, and Internal Lining Boards 28, may be layered in a jig by means of a robotic arm, or by other means, by which PU glue may be applied in-between layers such that a bond may be formed, joining the Individual Modular External Wall Panels 18, as appropriate.
    • d) The layer order may be described as follows:
    • i) Internal Lining Board with finished side facing down,
    • ii) EPS with the service grooves facing down,
    • iii) Metal Siding Layer 27 with finished side facing up,
    • iv) Metal Siding Layer 27 with finished side facing down,
    • v) EPS with the service grooves facing up,
    • vi) Internal Lining Board 28 with finished side facing up,
    • vii) Layers i to vii may be repeated as appropriate,
    • e) The Modular External Wall Panel 18 layers may then be vertically pressed by means of a pneumatic or hydraulic press for sufficient duration such that the adhesive may cure.


The Panelized Modular Building System 1, described herein presents a method of assembling and joining Individual Modular External Wall Panels in order to form an External Wall Panel 2, up to a desired length; the process consists of the following steps:

    • a) Two Individual Modular External Wall Panels 18, to be joined may be placed side by side facing the same direction such that the Internal Lining Boards 28, may be aligned together directly side by side.
    • b) A Steel Wall Stud 22, may be inserted with its wider profile side facing the Internal Lining Board 28 surface, positioned such that it may be in contact with both surfaces of the Internal Lining Boards 28.
    • c) The stud may then be fastened to the Internal Lining Board 28 of each Individual Modular External Wall Panel 18, by screws or glue or other means.
    • d) A Weatherproof Connection Mechanism 19, may then be inserted between the two Metal Siding Layers 27 of the adjoining Individual Modular External Wall Panels 18, as described in the figures.
    • e) Steps a to d may be repeated until the External Wall Panel 2, may reach its desired length, due to the repeating nature of this purposefully designed process, robotic assembly may be utilized, as the motions required for assembly are repetitive.
    • f) Window Panels 7, may be attached within the External Wall Panel 2, as described in the figures, by positioning the Window Panel 7, instead of the Individual Modular External Wall Panels 18, during steps a to d as required.
    • g) The plumbing, electrical and other services, may be installed by utilizing the service voids within the External Wall Panel, such that services may be located within the inside of the walls to where they are required, and may run along the top of the wall panel, under the Upper Wall Bearing Plates 20, services such as pipework and electrical wires may be cut to size and assembled ahead of time, due to the fact that their required dimensions may be of finite variations, due to the modular nature of the Modular Building System 1, and by utilizing standard service wall height locations.
    • h) The Lower Wall Bearing Plate 21, and the Upper Wall Bearing Plate 20, may be fitted
    • i) The Vertical Connection Rods may be inserted as required.
    • j) A clamp or jig may be fitted to the wall to ensure straightness and to secure the Lower Wall Bearing Plate 21, and the c in place
    • k) The voids may be filled with PU foam using foam injection into the filler holes, located in the Upper Wall Bearing Plate 20.
    • i) The Internal Wall Lining Layer may be applied to the internal surface of the assembled External Wall Panel 2, by applying the roll of internal lining material, that is greater in width, than the height of the finished External Wall Panel, such that it may be rolled out along the length of the internal surfaces of the External Wall Panel, and may be adhered by means of PU adhesive or by other means.
    • j) Plumbing, electrical, HVAC and other service fixtures may be fitted off as required.
    • k) Panels may be packaged, racked and readied for shipment.


The Panelized Modular Building System 1, described herein presents a method of constructing Individual Modular Internal Wall Panels 42; the process consists of the following steps:

    • a) EPS Foam Cores 46, may be prepared by means of a CNC controlled hot wire cutting machine, and may be profiled as described in the figures.
    • b) Individual Modular Internal Wall Panels 42, may then layered in a jig calibrated to hold the Internal Lining Boards 47, and the EPS Foam Cores 46 in their appropriate positions, and may be adhered together by means of adhesive being applied in-between layers; the layer order may be as follows:
    • i) Internal Lining Board 47 with finished side facing down,
    • ii) EPS Foam Cores 46,
    • iii) Internal Lining Board 47 with finished side facing up,
    • iv) Internal Lining Board 47 with finished side facing down,
    • v) EPS Foam Cores 46,
    • vi) Internal Lining Board 47 with finished side facing up,
    • vii) repeat layers i to iii as required
    • e) The Modular Internal Wall Panels 42 layers may then be vertically pressed by means of a pneumatic or hydraulic press for sufficient duration such that the adhesive may cure.


The Panelized Modular Building System 1, described herein presents a method of assembling and joining Individual Modular Internal Wall Panels 42, in order to form Internal Wall Panel 3 of a desired length, the process may consist of the following steps:

    • a) Two Individual Modular Internal Wall Panels 42 to be joined may be placed side by side.
    • b) Two Steel Wall Studs 22, may be inserted with their wider profile sides facing the Internal Lining Board 47 surfaces, positioned such that they may be in contact with both surfaces of adjoining Internal Lining Boards 47 and may be held captive by the profiles of the EPS Foam Cores 46,
    • c) The studs may or may not be fastened to the Internal Lining Boards 47 boards of each internal wall panel by screws, glue or other means.
    • e) Steps a to c may be repeated until the Internal Wall Panel 3, may reach the desired length,
    • f) Internal door jamb components may be attached to the ends of the Internal Wall Panel 3, wall where internal doors may be required.
    • g) plumbing, electrical and other services may be installed utilizing the service voids within the Internal Wall Panels 3, such that services may be located inside of the walls, as required.
    • i) Internal Vertical Connection Rods 45, may be placed within the Internal Wall Panel 3, as required
    • j) Upper Internal Wall Bearing Plates 43, and Lower Internal Wall Bearing Plates 44, may be fitted to the Internal Wall Panel 3, as per the figures.
    • j) A clamp or jig may be utilized in order to ensure straightness of the Internal Wall Panel 3, and to secure the Upper Internal Wall Bearing Plates 43, and Lower Internal Wall Bearing Plates 44, and Internal Vertical Connection Rods 45 in place,
    • k) The voids may be filled with PU foam 52, by means of foam injection, via the filler holes located in the Upper Internal Wall Bearing Plate 43, as per the figures,
    • i) The wall surfaces may have Internal Wall Lining Layers 41 applied to each side of the Internal Wall Panel 3, as required, similar to the process outlined for the External Wall Panel 2, assembly method described herein,
    • j) Plumbing, electrical, HVAC and other service fixtures may be fitted off as required
    • k) Panels may be packaged and racked and readied for shipment


The Panelized Modular Building System 1, described herein presents a method of constructing Floor Panels 4, Mid-Floor Panels 5, and Roof Panels 6; the process consists of the following steps:

    • a) EPS Foam Cores 54, may be prepared by means of a CNC controlled hot wire cutting machine, and may be profiled as described in the figures,
    • b) Floor joists may be prepared by means of roll forming or other manufacturing methods, and Female Inter-floor Locking Mechanisms 66 and Male Inter-floor Locking Mechanisms 65 may be attached or cut to in the Joists where required.
    • c) The floor joists may be positioned onto the strategically profiled edge of the EPS Foam Cores 54, as described in the figures, and services may be routed inside the Void 63 between the Floor Joists and the EPS Foam Core 54 as required, and a jig may be utilized in order to ensure straightness and accuracy of the Male Steel Floor Joist 58, and Female Steel Floor Joist 59, positions,
    • d) Floor Panel End Caps 57 may be situated at both ends of the Floor Panel 4, Mid-floor Panel 5, or Roof Panel 6, as described in the figures,
    • e) PU foam may be injected into Filler Holes 64, located in the Male Steel Floor Joist 58, and Female Steel Floor Joist 59 as described in the figures, and the PU foam 60 may be allowed to cure,
    • f) The various Upper and Lower Structural Layers bottom layers of the Floor Panels 4, Mid-Floor Panels 5, and Roof Panels 6, as described in the figures, may be positioned into a jig, or applied directly to the partially assembled panel, and may be adhered by means of PU adhesive or by other means, and may be compressed onto the panels, by means of a pneumatic press, hydraulic press, or by other means, such that the adhesive may be allowed to cure under pressure, forming a structural bond between the Structural layers and EPS Foam Core 54, as described in the figures, layers for multiple panels may be stacked together during manufacturing to achieve improved efficiency,
    • g) Floor and ceiling surfaces may be lined with their respective finishing materials, and may be attached by means of PU adhesive, or by other means,
    • h) Plumbing, electrical, and HVAC fixtures may be fitted off to the panels.
    • i) The panels may be packaged and prepared for shipment.


The Panelized Modular Building System 1, described herein presents a method of lining and finishing wall and ceiling surfaces of the prefabricated External Wall Panels 2, Internal Wall Panels 3, Mid-floor Panels 5, and Roof Panels 6; the process consists of the following steps:

    • a) An External Wall Panel 2, Internal Wall Panel 3, Mid-floor Panel 5, or Roof Panel 6, may be assembled as described by the respective processes described herein,
    • b) A roll of Internal Lining Material, which may be pre painted or colored, and may be strategically sized, such that the width of the roll is equal to or greater than the height of the finished External Wall 2, Internal Wall 3, or the width of the ceiling of the Mid-floor Panel 5, or Roof Panel 6, may be positioned at one end of the wall,
    • c) Adhesive may be applied to internal lining surface of the External Wall Panel 2, Internal Wall Panel 3, or the ceiling of the Mid-floor Panel 5, or Roof Panel 6, or directly to the finishing material itself, by means of adhesive rolling or by other means,
    • d) The Internal Lining Material may be rolled out along the length of the panel being lined, such that the Lining Material may be held under tension, and may be pressed to the panel surface, adhering the Internal Lining Material to the entire length and height of the External Wall Panel 2, Internal Wall Panel 3 or the ceiling of the Mid-floor Panel 5, or Roof Panel 6, such that a smooth, flat surface may be achieved.


The Panelized Modular Building System 1, described herein presents a method of assembling the Exterior Wall Butt Joining Bracket 11. The method consists of the following steps:

    • a) the U shaped channel may be manufactured with bolt holes or Key Shaped Slots such that it may be joined to the adjoining External Wall Panels 2, and adjoining Internal Wall Panels 3, as described in the figures,
    • b) The Structural U shaped Bracket 91 may be joined by means of bolts or slotted connection to the adjoining External Wall Panels 2 and adjoining Internal Wall Panel 3 on site providing a structural connection, as described in the figures,
    • c) Services may be connected within the U shaped Channel as required
    • d) The Straight External Wall Panel Siding Joiner 92, may be slid in-between the Metal Siding Layers 27, of the adjoining Exterior Wall Panels as outlined in the figures,


The Panelized Modular Building System 1, described herein presents a method of assembling the Exterior Wall Corner Brackets 12, the method consists of the following steps:

    • a) The L Shaped Bracket 93 may be manufactured with bolt holes or Key Shaped Slots such that it may be joined to the adjoining External Wall Panels 2, as described in the figures,
    • b) The L Shaped Bracket 93 may be joined by means of bolts or slotted connection to the adjoining External Wall Panels 2, on site, providing a structural connection, as described in the figures,
    • c) Services may be connected within the L Shaped Bracket 93 as required
    • d) The Boxed Corner Siding Joiner 94, may be slid in-between the Metal Siding Layers 27, of the adjoining Exterior Wall Panels 3, as outlined in the figures,


The Panelized Modular Building System 1, described herein presents a method of constructing Window Panels 7, the method consists of the following steps:

    • a) Components of the Structural Metal Frame 69 assembly may be manufactured to have joining components such as bolt holes or slotted connections as outlined in the figures, b) the Structural Metal Frame 71 assembly may be formed by means of welding, bolting, or attaching by other means, steel box sections, or other structural components together as outlined in the figures.
    • c) The Non-structural Window or Door Component 72, may be formed by means of roll forming, metal extrusion, or by other means as shown in the figures,
    • d) The Non-structural Window or Door Component 72, may be positioned inside the Structural Metal Frame 71 assembly as outlined in the figures,
    • e) Adjoining Individual Modular External Wall Panels 18, may be connected to the Strategically Shaped Vertical Window Profiles 75, by means of the Weatherproof Connection Mechanisms 19, and by slotting the Internal Lining Boards of the adjoining Individual Modular External Wall Panels 18, into the C Shaped Grooves 76, of the Strategically Shaped Vertical Window Profiles 75,
    • f) The Lower Horizontal Profiles 77 may then be positioned at the bottom of the window panel,
    • g) PU foam may then be injected into the voids formed between the Non-structural Window or Door Components 72, the Structural Metal Frame 71 assembly, and the adjoining Individual Modular External Wall Panels 18, such that the components may become attached together and a weather-tight connection may be formed between the Window Panel 7, and the adjoining Individual Modular External Wall Panels 18


The Panelized Modular Building System 1, described herein presents a method of manufacturing, constructing, transporting and assembling the Roofing System 8, the method consists of the following steps;

    • a) The individual structural components of the Roofing System may be manufactured and holes, tabs, and connection mechanisms may be created by means of roll forming, metal punching, laser cutting, or other manufacturing processes, as per the figures,
    • b) the Foldable Roof Trusses 108, may be assembled by joining the Folding Support Members 114, to the Sloping Member 113, by means of a Pinned Connection 115, by means of a single structural bolt, rivet or pin,
    • c) The Foldable Roof Trusses 108, may be folded flat such that they may be efficiently transported to site.
    • d) The Foldable Roof Trusses 108, and other roofing components may be transported to site,
    • e) The Roof Anchoring Bracket may be attached to the Assembled Roof Panels 6, by means of clipped connection described in the figures, or by screws or other means,
    • f) The Foldable Roof Trusses 108 are unfolded and attached to the Roof Anchoring Bracket by means of clipped connection described in the figures, or by screws or other means,
    • g) The Snap Together Roofing Purlins 109, may be attached to the Foldable Roof Trusses 108, by means of clipped connection described in the figures, or by screws or other means,
    • h) The Snap On Metal Roofing Layer 110 is attached by angling the Metal Roofing Layer such that the Male Profile 108, may fit under the Snap-on Roof Layer Connection Hooks 119, such that it may be held captive, The Snap On Metal Roofing Layer 110 is then laid flat such that the Female Hook 121, of the Snap On Metal Roofing Layer 110 may attach to the Snap Together Roofing Purlin 109, such that the Snap On Metal Roofing Layer 110 may become attached to the roof structure
    • i) Snap On Metal Roofing Layers 110 may be applied moving in the direction from the Male Profile 120 to the Female Hook 121, until the Roofing System is complete as required,


The Panelized Modular Building System 1, described herein presents a method of joining Internal Wall Panels 3 to other Internal Wall Panels 3 or External Wall Panels 2, while retaining the integrity of the pre-finished surfaces of the various prefinished panels; the process consists of the following steps:

    • a) Male Joining Mechanisms 39, or Female Joining Mechanisms 40, may be fitted to the Internal Wall Panels 3, or External Wall Panels 2, as described in the figures,
    • b) During final assembly on-site, the Male Joining Mechanisms 39 may be inserted into the larger holes of the Female Joining Mechanisms 40 of the adjoining wall panel,
    • c) The panel with the Male Joining Mechanisms 39, may then be lowered into its final position, causing a structural connection to be formed between the two panels,
    • d) The wall studs of the adjoining wall panels may then also be fastened at the top of the wall intersection to prevent the walls from moving vertically, and hence becoming dislodged from one another.


The Panelized Modular Building System 1, described herein presents a method of joining prefinished External Wall Panels 2 to prefinished Floor Panels 4, Mid-floor Panels 5 and Roof Panels 6, whereby External Wall Connection Brackets 10 may be utilized to attach to adjoining Floor Panels 4, Mid-floor Panels 5 and Roof Panels 6, whereby External Wall Panels 2, may then be located above or below the External Wall Connection Brackets 10, such that the Vertical Connection Rods 23 of the External Wall Panels 2, may be fastened to the External Wall Connection Brackets 10 and hence the adjoining panels, which may provide a structural connection throughout each of the panels, from the Roof Panels 6, down to the Foundation System 15, to the External Wall Panels, the process consists of the following steps:


The Panelized Modular Building System 1, described herein presents a method of joining prefinished External Wall Panels 2 and prefinished Internal Wall Panels 3 to prefinished Floor Panels 4, Mid-floor Panels 5 and Roof Panels 6, by means of a Structural Floor Joining Brackets 9 as described in the figures, whereby the process consists of the following steps:

    • a) A single or series of Floor Panels 4 or Mid-floor Panels 5, may be lowered into position
    • b) The Structural Floor Joining Brackets 9 may then be positioned at the end of the Floor Panels 4, Mid-floor Panels 5 or Roof Panels 6, running perpendicular to the length direction of the panels,
    • c) The Floor Panels 4, Mid-floor Panels 5 or Roof Panels 6, may then be fastened to the Structural Floor Joining Brackets 9 by bolts, screws or other means, via access through the strategically positioned Access Points 85,
    • d) Subsequent Floor Panels 4, Mid-floor Panels 5 or Roof Panels 6 may then be positioned on the other side of the Structural Floor Joining Brackets 9 and may be fastened by repeating step c
    • e) The Internal Wall Panel 3, may then be lowered on top of the Structural Floor Joining Brackets 9, such that the Disc Shaped Ends 87, that may have been added to the Vertical Connection Rods 23, of the adjoining Internal Wall Panel 3,
    • f) The Sliding Locking Plate 82, of the Structural Floor Joining Brackets 9, may then be shifted to the Closed Position 89, such that the Structural Floor Joining Brackets 9 becomes fastened to the Internal Wall Panel 3, and locks the Internal Wall Panel 3 into place as shown in FIG. 77.


The Panelized Modular Building System 1, described herein presents a method of joining prefinished Internal Wall Panels 3 to prefinished Floor Panels 4, Mid-floor Panels 5 and Roof Panels 6, the process consists of the following steps:

    • a) The floor or mid-floor of the structure may be assembled in place
    • b) The External Wall Panels 2 of one side of the structure may be positioned and attached to the Floor Panels 4, or Mid-floor Panels 5, via the External Wall Connection Brackets 10 as described in [0232],
    • c) The Internal Wall Panels 3, may be lowered into positon on top of the Floor Panels 4, or Mid-floor Panels 5, such that the Strategically Placed Holes 53, situated in the Floor Panels 4, or Mid-floor Panels 5, may accept the Internal Vertical Connection Rods 45, of the Internal Wall Panels 3, such that a pinned connection may be formed, and no invasive fastening may be required to the Floor Panels 4, or Mid-floor Panels 5,
    • d) The External Wall Panels 2 on the other side of the structure may be positioned and attached to the Floor Panels 4, or Mid-floor Panels 5, via the External Wall Connection Brackets 10 as described in [0232],
    • e) The subsequent upper level of Mid-Floor Panels 5, or Roof Panels 6, may then be placed onto the structure, such that the Internal Vertical Connection Rods 45, on the top of the Internal Wall Panels 3, may locate into the Strategically Placed Holes 53, on the underside of the upper level of Mid-Floor Panels 5, or Roof Panels 6, that are being placed on top of the Internal Wall Panels 3, such that the Internal Wall Panels 3, may become captive in between the Floor Panels 4, Mid-floor Panels 5, or Roof Panels 6, situated above and below the Internal Wall Panels 3,
    • f) The upper level of Mid-Floor Panels 5, or Roof Panels 6, may then be fastened to the structure by means of attachment through the External Wall Connection Brackets 10, to the External Wall Panels 2, such that a the Internal Wall Panels 3, may be fully restrained and structural integrity of the structure may be achieved, whilst only utilizing pinned connections for the attachment of the Internal Wall Panels 3, to the Structure, except for the case of where the Internal Wall Panels 3, may be performing a structural function at the end of the span of a Mid-floor panel 5, or Roof Panel 6, in which case a Structural Floor Joining Brackets 9 may be utilized to allow structural connection to be made,


The Panelized Modular Building System 1, described herein presents a method of constructing the building foundation utilizing the Foundation System 15, the method consists of the following steps;

    • a) Helical Screw Piles 95, may be driven into the ground by means of a hydraulic rotary drill attached to an excavator, or by other means, such that care is taken to position the Helical Screw Piles 95 as accurately as possible in terms of both position and depth into the ground,
    • b) Flexible Foundation Mounting Brackets 96, may then be loosely attached to the Slotted Mounting Plates 98, of the Helical Screw Piles 95, and the Structural Floor Bearers 97, may be placed on top of the Flexible Foundation Mounting Brackets 96, and loosely fastened.
    • c) Floor Panels 4, may then be placed in between the Structural Floor Bearers 97, and the Floor Panels may be bolted to the Structural Floor Bearers 97 one at a time, ensuring that Floor Panels are also interconnected by positioning and utilizing the connection between the Male Steel Floor Joists 58 and the Female Steel Floor Joists 59.
    • D) Once all of the floor Panels 4, have been positioned and fastened to the Structural Floor Bearers 97, the Threaded Rod and Fastening Nut 104, and the Mounting Bolts 101, of the Flexible Foundation Mounting Brackets 96, may be fully fastened, providing a structural connection between the floor structure and the Foundation System, while maintaining room for error in the positioning of the Helical Screw Piles 95.


The Panelized Modular Building System 1, described herein presents a method of assembling the various finished modular panels on a site to form a Finished Modular Building 131; the process consists of the following steps:

    • a) The Foundation System may be installed and levelled as per [0235]
    • b) Bottom floor External Wall Panels 2, and Internal Wall Panels 3, may be installed in order from one corner of the structure to the other
    • c) Services may be connected at wall junctions, at the top of the wall panels,
    • d) Mid-Floor Panels 5, may be lifted into place and attached to one another by means of utilizing the connection between the Male Steel Floor Joists 58 and the Female Steel Floor Joists 59, whereby Structural Floor Joining Brackets 9 may be installed in-between Mid-floor Panels 5 where a structural connection is required at the end of a Mid-floor Panel 5, span,
    • e) External Wall Connection Brackets 10, may be utilized to fasten the lower External Wall Panels 2, to the Mid-floor Panels 5, providing a structural connection,
    • f) Second floor External Wall Panels 2, and Internal Wall Panels 3, may be installed in order from one corner of the structure to the other
    • g) Second floor services may be connected at wall junctions
    • h) Roof Panels may be lifted into place and attached to one another by means of utilizing the connection between the Male Steel Floor Joists 58 and the Female Steel Floor Joists 59, whereby Structural Floor Joining Brackets 9 may be installed in-between Roof Panels 6 where a structural connection is required at the end of a Roof Panel 6, span,
    • i) External Wall Connection Brackets 10, may be utilized to fasten the second floor External Wall Panels 2, to the Roof Panels 6, providing a structural connection,
    • j) The Roofing System may be installed,
    • k) The Decorative Siding System 17, may be installed where decorative siding may be required,
    • l) Internal Doors may be installed,
    • m) Cabinetry and other completion works may be undertaken


The Panelized Modular Building System 1, described herein presents a method of attaching alternative decorative exterior siding panels to the External Wall Panels 2, whereby the process consists of the following steps:

    • a) The External Wall Panel 2, is assembled as utilizing the Substitute Weather-proof Connection Mechanisms 122,
    • b) Siding Mounting Battens 123, are applied to the Substitute Weather-proof Connection Mechanisms 122, such that Siding Mounting Battens 123, cover the area where the Decorative Siding Panels 125, are to be installed,
    • c) Decorative Siding Clips 124, are attached to the Decorative Siding Panels 125, such that the Decorative Siding Panels 125, may by clip style connection, attach to the Siding Mounting Battens 123, and hence the External Wall Panel 2, where the Decorative Siding Panels 125, are to be installed.

Claims
  • 1. A method of forming a connection between two or more components of a modular building system, comprising: positioning at least first and second components proximate each other such that there is a void therebetween; andplacing a liquid polyurethane (PU) foam between said first and second components in said void; andcuring said PU foam so as to form a connection between said first and second components.
  • 2. The method of claim 1, wherein said first and second components are individual modular external wall panels, and comprising performing said method on two or more individual modular external wall panels so as to form an external wall panel of a desired length.
  • 3. The method of claim 1, further comprising placing a first metal siding layer adjoining said first component and a second metal siding layer adjoining said second component, wherein said connection is weathertight.
  • 4. The method of claim 1, comprising positioning three or more of said components proximate each other serially such that there is a void between serial components, and wherein PU foam is placed in voids between only some of the adjoining components.
  • 5. The method of claim 1, wherein said first and second components are individual modular internal wall panels, comprising performing said method on two or more individual modular internal wall panels so as to form an internal wall panel of a desired length.
  • 6. The method of claim 1, further comprising forming a structural attachment between a panel comprising a floor panel, mid-floor panel, or roof panel, and one or more structural joint members on either side of said panel, thereby distributing any load in the first and second components over a spanning distance of the panel via the PU foam.
  • 7. The method of claim 1, wherein said first and second components comprise window panels, further comprising positioning said first and second components proximate a structural metal frame, such that said connection is made between said first component and said structural metal frame and between said second component and said structural metal frame, wherein said window panels are non-structural.
  • 8. The method of claim 1, wherein said first component is a window panel and said second component is an individual modular external wall panel.
  • 9. The method of claim 1, further comprising connecting said first and second components to structural studs and/or vertical connection rods.
  • 10. The method of claim 1, wherein said PU foam is also positioned between said first and second components and one or more structural members of said modular building system in order to reinforce said one or more structural members.
  • 11. A method of forming part of a modular building system structure, comprising joining a first preassembled panel comprising one or more first connection mechanisms to a second preassembled panel comprising one or more second connection mechanisms, wherein the one or more first connection mechanisms are connected to respective second connection mechanisms, and wherein either the one or more first connection mechanisms or the one or more second connection mechanisms are slid within the other such that the first and second connection mechanisms become interlocked.
  • 12. The method of claim 11, further comprising applying one or more finishing materials to each of said first and second preassembled panels prior to joining said first and second preassembled panels.
  • 13. The method of claim 11, wherein said first preassembled panel and said second preassembled panel are floor panels, mid-floor panels, or roof panels, wherein said first connection mechanisms are positioned on a joint of said first preassembled panel, wherein said second connection mechanisms are positioned on a joist of said second preassembled panel, wherein said first connection mechanisms are inserted into said second connection mechanisms by sliding said first preassembled panel toward said second preassembled panel.
  • 14. The method of claim 11, wherein said one or more second connection mechanisms are within a sliding lock plate of a structural floor joining bracket, and said one or more first connection mechanisms are on a bottom side of one or more vertical connection rods within an internal wall panel, such that the bottom side of said one or more vertical connection rods may insert into said one or more second connection mechanisms, such that said sliding lock plate is movable within a rectangular hollow section, such that said one or more first connection mechanisms become captive with said one or more second connection mechanisms, such that a connection is formed between said structural floor joining bracket and said internal wall panel.
  • 15. The method of claim 11, further comprising affixing said one or more first connection mechanisms to an end of a first internal wall panel, and locating said second connection mechanisms on a face of an external wall panel or a second internal wall panel, such that said first internal wall panel is attachable at a 90 degree angle to said external wall panel or said second internal wall panel.
  • 16. The method of claim 11, wherein one or more of said first or second connection mechanisms comprises a sloped edge or sloped face, such that when said first and second connection mechanisms interlock said sloped edge or sloped face causes the first and second connection mechanisms to tighten with one another, thereby drawing said first and second preassembled panels closer together and forming a tensioned joint.
  • 17. The method of claim 11, wherein said first connection mechanisms are male or female, and wherein corresponding ones of said second connection mechanisms are the other of male and female.
  • 18. A method of adjoining a first panel to a second panel using a pinned connection, wherein said first panel is an internal wall panel and said second panel is a floor panel, mid-floor panel, or roof panel, comprising inserting vertical connection rods of the first panel into holes in the second panel such that when ends of the second panel become fixed, the first panel becomes captive to the second panel to enable use of the pinned connection in a non-invasive manner.
  • 19. The method of claim 17, further comprising applying pre-finished surfaces to each of said first and second panels prior to said inserting.
Parent Case Info

This application claims the priority benefit of U.S. Provisional Pat. App. No. 63/449,311 to Webster, filed on Mar. 1, 2023 and entitled “Structural Panel Manufacturing and Connection System for Buildings,” which is fully incorporated by reference herein in its entirety.

Provisional Applications (1)
Number Date Country
63449311 Mar 2023 US