Patent Application
20240410163
The present invention relates generally to modular and manufactured building systems and methods. More specifically, the present invention relates to modular and manufactured construction of single-family housing, multi-family housing, commercial, and/or retail buildings. Even more specifically, the present invention relates to using certain materials, polymer formulas, assembly mechanisms and techniques to manufacture and assemble the modular buildings.
The construction industry is volatile in nearly every aspect. The pricing and availability of building materials fluctuates constantly and is unpredictable. Building projects are subject to changing labor costs and in some instances, labor shortages. The construction timetable is dependent on numerous unknowable factors, including necessary inspections, supply chain issues, timely performance of contractors and subcontractors, weather at the site, and other disruptions construction site. Furthermore, traditional construction requires specific workflow wherein one phase of construction cannot begin without completion of the previous phase. For example, site excavation must be completed before construction of the structure can begin.
To address some of these issues, some in the industry have utilized modular construction. Modular construction may also be called prefabricated construction, pre-panelized construction, or other terms. Generally, modular constructions consists of fabricating some or all of a building offsite in a controlled environment then transporting the pre-fabricated elements to the site for quick assembly. In some cases, particularly with smaller single-family homes, the entire structure may be manufactured offsite, transported to the site, and installed in place. In other cases, various portions of the building are constructed off-site then are assembled onsite in a particular manner. All or some of the building may be prefabricated.
With modular construction, some or all of a build may be constructed in a controlled indoors environment at an offsite factory or the like. This eliminates weather delays or other potential obstacles associates with construction onsite. Furthermore, construction of the building may begin offsite while the site is still be excavated or otherwise prepared. In other words, modular construction does not have to proceed as linearly as traditional construction, which can increase efficiency and reduce construction time and costs. Furthermore, being able to produce buildings a in more assembly line manner can further increase efficiency and reduce costs. For example, one factory may produce the same line of modular single-family houses in repetition.
Despite the advantages of modular construction, many drawbacks still exist that have, so far, prevented modular construction from becoming widespread. First, finding the right materials for modular construction is difficult. Traditional building materials are not necessarily ideal for prefabrication. Builders have struggled with finding and working with effective materials. Furthermore, assembly of prefabricated pieces has compounded these issues. Difficulties in utilizing effective materials and in assembling the prefabricated components can neutralize the potential advantages in reduced costs and efficiency that modular building could bring. These issues are large enough the modular construction still only accounts for a small minority of construction projects.
Therefore, it is desirable to provide a system and method for fabricating modular components with effective materials and assembly mechanisms.
The instant invention provides for a novel modular fiberglass wall components and connections system and method. In a preferred embodiment, the invention utilizes fiberglass as the primary material in the components. The invention utilizes a novel molding process for manufacturing the components. The invention utilizes new primary sheathing material and adjoining and locking mechanisms. The instant invention reduces the need for several other materials used in typical construction, including lumber, sheetrock, siding, and paint.
In an exemplary embodiment of the present invention, the building to be constructed is broken into various modules or components constructed separately, including roof components, wall components, and floor components. Embodiments of the present invention utilize various component connections depending on the type: roof to wall, wall to wall, floor to floor, and roof to roof. The various components are then assembled onsite with the connections.
The foregoing and other objects are intended to be illustrative of the invention and are not meant in a limiting sense. Many possible embodiments of the invention may be made and will be readily evident upon a study of the following specification and accompanying drawings comprising a part thereof. Various features and subcombinations of invention may be employed without reference to other features and subcombinations. Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of this invention and various features thereof.
Preferred embodiments of the present invention, illustrative of the best mode in which the applicant has contemplated applying the principles, is set forth herein and is shown in the figures attached hereto.
As required, a detailed description of the various embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the principles of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
The instant invention provides for a novel modular fiberglass wall components and connections system and method. In a preferred embodiment, each building is broken into several modules or components for individual construction offsite. In some embodiments, the size of the modules is determined by the maximum shipping dimensions permitted by the department of transportation. This requires modules that exceed the allowable dimensions to be reconfigured for shipping. Individual modules are later assembled together onsite as described herein.
In some embodiments, the primary material used to construct the components is fiber reinforced plastic. By utilizing the many beneficial qualities of fiberglass the invention eliminates lumber, sheetrock, siding, paint, and other traditional building components. In some embodiments, a mold is used to create the components. The specific type of polymer and fiber is dependent on the geographic region and the structural requirements of the local jurisdiction.
In some embodiments, internal structural fiberglass members reinforce the walls, roof, and floor from applied forces as well as act as conduits for the electrical system. In some embodiments, the wall, roof, and floor assemblies are comprised of an inner layer of fiberglass, open cell foam insulation, and an exterior layer of fiberglass. The exterior and interior fiberglass layers provide structural rigidity and also serve as a moisture and air barrier and the finished surface. The open cell foam insulation will meet thermal building requirements as well as provide the additional structural reinforcement and acoustic isolation.
In some embodiments, there are at least four primary connections: roof to wall, wall to wall, floor to floor, and roof to roof. In some embodiments, the roof to wall connection consists of a mortise and tenon joint, self-locking implanted cotter pin, and epoxy. In some embodiments, the wall to wall, floor to floor, and roof to roof connection use a lap joint and epoxy adhesive. The mechanism that allows reconfiguration is a cam action lock and hinge which allows roof and wall components to fold and unfold.
It will be appreciated that the foregoing may be utilized for construction of other structures, including emergency disaster relief housing, microunits for affordable housing developments, recreational usage for hunters and outdoorsman, boats and house boats, and other utility structures.
The foregoing and other objects are intended to be illustrative of the invention and are not meant in a limiting sense. Many possible embodiments of the invention may be made and will be readily evident upon a study of the following specification and accompanying drawings comprising a part thereof. Various features and subcombinations of invention may be employed without reference to other features and subcombinations. Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of this invention and various features thereof.
This application claims priority to co-pending U.S. Nonprovisional Patent Application Ser. No. 63/471,858 filed Jun. 8, 2023, the entire disclosures of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63471858 | Jun 2023 | US |
