Modular construction system

Information

  • Patent Grant
  • 6272802
  • Patent Number
    6,272,802
  • Date Filed
    Thursday, November 18, 1999
    25 years ago
  • Date Issued
    Tuesday, August 14, 2001
    23 years ago
  • Inventors
  • Examiners
    • Callo; Laura A.
    Agents
    • Holland & Knight LLP
Abstract
The present invention relates to a modular building system. The system employs various building elements, which are interconnected by way of scarf joints. The building elements are connected to form a building module. The modules, in turn, can be interconnected to form a larger structure such as a dwelling. Additionally, the present system allows fixtures, such as window and door frames, to be incorporated into a completed dwelling. The details of the various components of the system of the present invention, and the manner in which they interrelate, will be described in greater detail hereinafter.
Description




BACKGROUND OF THE INVENTION




1. Field of the Invention




This invention relates to a modular building system, and more particularly pertains to a building system employing interlocking construction elements.




2. Description of the Related Art




The world population has grown at an exponential rate in recent decades. One of the biggest problems created by surging population figures is housing. An even bigger problem is the absence of affordable housing. Housing costs are typically driven by two factors: the cost of building materials; and the cost of labor. The cost of labor, in turn, is dictated by the time necessary to build a structure and the skill level of the laborers. One of the many efforts to decrease housing costs comes in the form of modular housing. Through modular housing, both material costs and labor costs can be drastically reduced.




Often times these modular systems utilize concrete or mortar slabs in constructing the final product. Examples of such systems include U.S. Pat. Nos. 5,359,825 to Makarov; U.S. Pat. No. 5,643,488 to Lee; U.S. Pat. No. 4,712,352 to Low; and U.S. Pat. No. 4,590,729.




Other efforts at modular systems employ multiple disconnectable fasteners or elaborate tongue-in-groove systems. Examples of these efforts include U.S. Pat. Nos. 5,609,003 to Jouty and U.S. Pat. No. 5,638,651 to Ford. Still yet other modular systems are primarily designed for structures other than dwellings. An example of such is U.S. Pat. No. 4,685,829 to Matiere.




While each of these modular systems achieves its particular objective, they all have a common result: a modular structure that looks modular.




Therefore, it is an object of this invention to provide an improvement which overcomes the aforementioned inadequacies of the prior art devices and provides an improvement which is a significant contribution to the advancement of modular home construction.




Another object of this invention is to enable modular construction systems to produce dwellings with a non-modular appearance.




Another object of the present invention is to permit a dwelling to be constructed from building elements that are easily interconnected.




Yet another object of the present invention is to provide a modular system which comprises individual building elements which are inexpensive and easy to manufacture.




Still yet another object of the present invention is to create a modular construction system that allows for the modular incorporation of doors and windows at desired locations.




The foregoing has outlined some of the pertinent objects of the invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.




SUMMARY OF THE INVENTION




For the purpose of summarizing the invention, this invention comprises a modular building system employing interlocking building elements. Through the use of the system dwellings can be easily constructed and maintained.




The system employs many different building elements, one of which is a fastening piece. This fastening piece has a scarf joint formed within a forward edge of the piece running the entire length of the first surface.




First and second assembly pieces constitute additional building elements of the system. Each of the pieces includes a first scarf joint formed proximate a rearward edge of the piece which runs the length of the outer surface. Likewise, a second scarf joint is formed proximate the forward edge of the piece and runs the length of the inner surface. Additionally, a transverse scarf joint is formed perpendicular to the second scarf joint and runs the entire width of the first end. This transverse scarf joint is interconnected to the first end of the fastening piece. In a similar fashion, the transverse scarf joint of the second assembly piece is interconnected to the second end of the fastening piece.




Additional building elements are present in the form of a series of panels. Each of the panels is defined by a rounded forward surface and a planar rearward surface. The panels additionally include upstanding upper and side edges, and a lower scarf joint. The panels are adapted to be slid in between the first and second assembly pieces, with the upstanding side edges being received within the second scarf joints of the assembly pieces and with the upstanding upper edge of each panel being positioned within the scarf joint of the adjacent panel. In this manner a fluid tight seal is created between adjacent panels.




Finally, a second fastening piece is secured to the second ends of the first and second assembly pieces with the series of panels secured therebetween. The first and second assembly pieces, the first and second fastening pieces, and the series of panels thus form a complete modular unit. An elongated joining piece can be secured within the facing first scarf joints of adjacent assembly pieces to permit the coupling of adjacent modular units.




The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.











BRIEF DESCRIPTION OF THE DRAWINGS




For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:





FIG. 1

is a front elevational view of a dwelling constructed from the modular system of the present invention.





FIG. 2

is an elevational view of one fastening piece of the system.





FIG. 3

as is a perspective view of one fastening piece of the system.





FIG. 4

is an elevational view of one assembly piece of the system.





FIG. 5

is a perspective view of one assembly piece of the system.





FIG. 6

is an elevational view of one panel of the system.





FIG. 7

is a perspective view of one panel of the system.





FIG. 8

is an elevational view of one joining piece of the system.





FIG. 9

is a perspective view of one joining piece of the system.





FIG. 10

is a perspective view of a partially constructed modular unit.





FIG. 11

is a perspective view of the partially constructed modular unit receiving a number of panels.





FIG. 12

is a perspective view of a series of panels interconnected with one another.





FIG. 13

is a view of a completed modular unit.





FIG. 14

is a view of a modular unit containing a door frame.





FIGS. 15-16

are views of modular units containing windows.





FIGS. 17-21

are elevational views of various modular unit shapes that can be employed in the system of the present invention.




Similar reference characters refer to similar parts throughout the several views of the drawings.











DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT




The present invention relates to a modular building system. The system employs various building elements, which are interconnected by way of scarf joints. The building elements are connected to form a building module. The modules, in turn, can be interconnected to form a larger structure such as a dwelling. Additionally, the present system allows fixtures, such as window and door frames, to be incorporated into a completed dwelling. The details of the various system components, and the manner in which they interrelate, will be described in greater detail hereinafter.





FIG. 1

illustrates a dwelling construction


10


in accordance with the system of the present invention. The entire structure


10


is formed from modular units. The modular units, in turn, are formed from interlocking building elements. These elements include: fastening pieces; assembly pieces; panels; and joining pieces. Each of the fastening pieces


20


are defined by first and second surfaces (


22


and


24


respectively), and first and second ends (


26


and


28


respectively). With reference to

FIGS. 2-3

, the scarf joint


32


of the fastening piece


20


is depicted. In the preferred embodiment, this scarf joint


32


is formed within a forward edge of the fastening piece


20


and runs the entire length of the first surface


22


. The preferred nominal dimensions of the fastening piece are as follows: 2 inches in height; 4 inches wide; 2 feet 10 inches in depth; with the scarf joint measuring ½ inch wide and ½ inch high. Fastening pieces with differing dimensions, however, can be employed.





FIGS. 4-5

illustrate one of the assembly pieces


34


employed in the system of the present invention. All of the assembly pieces of the system are identical, thus only one will be described in detail. The assembly piece


34


is defined by inner and outer surfaces (


36


and


38


respectively) and first and second ends (


42


and


44


respectively). Furthermore, a series of scarf joints are formed within the assembly piece


34


. Specifically, a first scarf joint


46


is formed proximate a rearward edge of the piece and runs the length of the outer surface


38


. Similarly, a second scarf joint


48


is formed proximate a forward edge of the piece and runs along the length of the inner surface


36


. In the preferred embodiment, the second joint


48


is slightly larger than the first


46


. With continuing reference to

FIGS. 4-5

, the transverse scarf joint


52


ofthe assembly piece is depicted. This joint


52


is formed perpendicular to the second scarf joint


48


and runs the entire width of the first end


42


. In the preferred embodiment, the transverse scarf joint


52


has first and second extents (


54


and


56


respectively) of differing heights. In other words, one side of the second scarf joint


48


runs longer than the other. The elongated side of the second scarf joint


48


is adapted to be interconnected with scarf joint


32


of fastening piece


20


.




The assembly piece


34


has preferred nominal dimensions of 2 inches in height; 4 inches in width; and 8 feet in depth. The preferred dimensions of the scarf joints are as follows: first scarf joint


46


is formed ½ inch from the rearward edge and has a width of {fraction (5/16)} inch and a height of ½ inch. The second scarf joint


48


is formed ½ inch from the forward edge and has a width of {fraction (9/16)} inch and a height of ½ inch. Finally, transverse scarf joint


52


is formed at the lower end and has a first height of 1½ inch and a second height of 1 inch. Again, assembly pieces of differing dimensions, containing scarf joints of differing dimensions, can readily be employed within the system of the present invention.





FIG. 10

illustrates the manner in which the assembly pieces are interconnected to opposing sides of fastening piece


20


. Specifically, the transverse scarf joint


52


of the first assembly piece


34


is interconnected to the first end


26


of fastening piece


20


. Likewise, the transverse scarf joint


52


of the second assembly piece


34


is interconnected to the second end


28


of fastening piece


20


. Adhesives and bolts


58


are preferably utilized to couple the assembly pieces to the fastening piece. Furthermore, anchoring bolts


60


can be employed to secure the fastening piece


20


to the ground, or to an adjoining building module. After the assembly pieces


34


are connected, the U-shaped building module


62


depicted in

FIG. 10

is achieved.




The U-shaped building module


62


is adapted to receive a series of panels


64


. Each of the panels


64


are of an identical construction, thus only one will be described in detail. The panel


64


, depicted in

FIGS. 6-7

, is defined by a rounded forward surface


66


and a planar rearward surface


68


. The rounded surface


66


preferably takes a log like appearance. Furthermore, panels


64


include upstanding upper


72


and side edges


74


, as well as a lower scarf joint


76


. The panel


64


is preferably 2¾ inches in height and 2 feet 11 inches in depth. Furthermore, the upstanding upper edge


72


is preferably {fraction (7/16)} inches in height and ½ inch wide. Similarly, the scarf joint


76


is preferably {fraction (7/16)} inches in height and ½ inch wide. Again, panels of differing dimensions can be employed within the system.




With reference now to

FIG. 11

, each of the panels


64


is slid in between the first and second assembly pieces


34


with the upstanding side edges


74


being received within the second scarf joints


48


of the assembly pieces


34


. Furthermore, scarf joint


76


of the first panel


64


within the module


62


fits into the scarf joint


32


of fastening piece


20


. The scarf joint


76


of the second panel


64


, in turn, fits over the upstanding upper edge


72


of the lower panel


64


. These interconnections create a fluid tight seal between adjacent panels without the need for adhesives, nails or bolts. Furthermore, the adjacent panels give a log cabin appearance to the finished dwelling.




The building module is completed by securing a second fastening piece


78


to the second ends


44


of the first and second assembly pieces


34


. As can be appreciated, the scarf joint of the second fastening piece


78


is positioned over the upstanding edge of the uppermost panel. With the series of panels


64


secured between the first and second assembly pieces


34


and the first and second fastening pieces


20


,


78


a building module


82


is completed, note FIG.


13


.

FIG. 1

illustrates a completed dwelling


10


formed from various building modules


82


. Furthermore,

FIGS. 17-21

illustrate other possible building module configurations. These configurations are achieved by employing angled upper panels and fastening pieces. Such modules find particular application adjacent gabled roofs.




The U-shaped modular unit


62


can accept other structural elements such as windows and doors.

FIGS. 15-16

illustrate window frames


84


which have been slid into positioned within the scarfs of the opposing assembly pieces. In the preferred embodiment, these are plastic or aluminum fixed glass guillotine windows.

FIG. 14

illustrates a door frame


86


similarly positioned between the first and second assembly pieces. In this manner, a user can selectively position various doors and windows in the final completed dwelling.




Adjacent modular units are interconnected by way of elongated joining pieces


88


. The joining pieces are identical in construction, so only one will be described in detail.

FIGS. 8-9

illustrate the joining piece


88


of the present invention. The piece is dimensioned to fit into the first scarf joint


46


of the assembly piece


34


. In the preferred embodiment, the joining piece has nominal dimensions of 1 inch in height; {fraction (5/16)} inches in width and 8 feet in depth. Obviously, other joining pieces employing other dimensions are within the scope of the present invention. Each joining piece should be sufficiently wide enough to be secured within the facing first scarf joints


46


of adjacent assembly pieces


34


. In the preferred embodiment, the joining pieces are secured in place by way of an adhesive.

FIG. 12

illustrates the manner in which a joining piece is employed in coupling adjacent modular units.




The present disclosure includes that contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.




Now that the invention has been described,



Claims
  • 1. A modular building system employing interlocking building elements for use in constructing dwellings, the system comprising in combination:a fastening piece having first and second surfaces, and first and second ends, a scarf joint formed within a forward edge and running the entire length of the first surface; first and second assembly pieces, each of the assembly pieces having inner and outer surfaces, and first and second ends, a first scarf joint formed proximate a rearward edge and running the length of the outer surface, a second scarf joint formed proximate a forward edge and running the length of the inner surface, a transverse scarf joint formed perpendicular to the second scarf joint and running the entire width of the first end, the transverse scarf joint having first and second extents of differing widths, the transverse scarf joint of the first assembly piece being interconnected to the first end of the fastening piece, the transverse scarf joint of the second assembly piece being interconnected to the second end of the fastening piece; a series of panels, each of the panels having a rounded forward surface, a planar rearward surface, upstanding upper and side edges, and a lower scarf joint, each of the panels being slid in between the first and second assembly pieces with the upstanding side edges being received within the second scarf joints of the assembly pieces and with the upstanding upper edge of each panel being positioned within the scarf joint of the adjacent panel to create a fluid tight seal between adjacent panels; a second fastening piece being secured to the second ends of the first and second assembly pieces with the series of panels secured therebetween, the first and second assembly pieces, the first and second fastening pieces, and the series of panels forming a modular unit; an elongated joining piece being secured within the facing first scarf joints of adjacent assembly pieces to permit the coupling of adjacent modular units.
  • 2. A modular building system for use in constructing dwellings, the system comprising:a fastening piece having first and second surfaces, and first and second ends, a scarf joint formed within a forward edge; first and second assembly pieces, each of the assembly pieces having inner and outer surfaces, and first and second ends, a first and second scarf joints, a transverse scarf joint formed perpendicular to the second scarf joint, the transverse scarf joint of the first assembly piece being interconnected to the first end of the fastening piece, the transverse scarf joint of the second assembly piece being interconnected to the second end of the fastening piece; a series of panels, each of the panels having upstanding side edges, and each of the panels being slid in between the first and second assembly pieces with the upstanding side edges being received within the second scarf joints of the assembly pieces.
  • 3. The system as described in claim 2 wherein each of the panels includes a lower scarf joint and an upper edge which allows adjacent panels to be coupled in a fluid tight manner.
  • 4. The system as described in claim 2 wherein each of the panels includes a rounded forward surface such that a series of panels creates a log cabin appearance.
  • 5. The system as described in claim 2 wherein each transverse scarf joint is formed of two extents of differing widths with one extent adapted to be coupled to the scarf joint of the fastening piece.
  • 6. The system as described in claim 2 wherein the first and second assembly pieces, fastening piece, and series of panels from a modular unit.
  • 7. The system as described in claim 6 further comprising an elongated joining piece secured within the facing first scarf joints of adjacent assembly pieces to permit the coupling of adjacent modular units.
  • 8. The system as described in claim 2 further comprising a window frame slidably positioned intermediate adjacent panels.
  • 9. The system as described in claim 2 further comprising a door frame slidably positioned within the opposing second scarf joints of the first and second assembly pieces.
Priority Claims (1)
Number Date Country Kind
PI/HN98/160 Oct 1998 HN
CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from Honduran application number PI/HN98/160, filed Nov. 19, 1998.

US Referenced Citations (15)
Number Name Date Kind
794595 Ducker Jul 1905
2021341 Ward Nov 1935
3979862 Hamilton et al. Sep 1976
4567701 Biggs et al. Feb 1986
4577444 Sanderson Mar 1986
4590729 Hegazi May 1986
4685829 Matiere Aug 1987
4712352 Low Dec 1987
4742657 Veech May 1988
5359825 Makarov Nov 1994
5577356 Hubbard et al. Nov 1996
5609003 Jouty Mar 1997
5638651 Ford Jun 1997
5643488 Lee Jul 1997
5864997 Kelly Feb 1999
Foreign Referenced Citations (6)
Number Date Country
12427 Sep 1977 AU
75780 Jun 1976 GB
2-197638 Aug 1990 JP
3-224929 Oct 1991 JP
6-73810 Mar 1994 JP
36668 Jan 1923 NO