Patent Application
20230160196
Conventional building construction typically involves site-specific designs that are constructed entirely or nearly entirely on-site. There is a desire for modular building designs that can be assembled at a remote site and brought to a building site for assembly in various configurations that can be repeated or altered among various sites.
Representative embodiments of the present technology include a structural system including one or more modules. A module may include a first upper chord oriented along a length of the module, a first lower chord oriented along the length of the module, a second upper chord positioned opposite the first upper chord, parallel to the first upper chord, a second lower chord positioned opposite the first lower chord, parallel to the first lower chord, and a plurality of rib assemblies positioned between the first upper chord, the first lower chord, the second upper chord, and the second lower chord, the rib assemblies extending along a width of the module perpendicular to the chords. At least one of the chords may include a plurality of chord portions joined together with one or more connector plates. Two of the rib assemblies may include shear keys configured to be received in support structures, such as piers at a final installation site. In some embodiments, each chord portion includes a plurality of arrays of holes. The rib assemblies may include two vertical column beams and two or more horizontal crossbeams connecting the column beams to each other. The shear keys may project downwardly from the vertical column beams.
Another representative embodiment of the present technology includes a method of making a structure. Making the structure may include making a module of the structure. The method may be at least partially performed at a first location (such as a factory) that is remote from a second location (such as a final outdoor installation location of the structure). The method may include positioning shear keys (attached to the module) into pockets formed in piers (such as concrete piers) at the final installation location. The method may include leveling the module by positioning shims in the pockets under the shear keys or moving the shear keys within the pockets. Empty space in the pockets may be filled with filler material, eliminating a need for bolting the module to the piers.
Other features and advantages will appear hereinafter. The features described above can be used separately or together, or in various combinations of one or more of them.
In the drawings, wherein the same reference number indicates the same element throughout the several views:
The present technology is directed to modular structures (which may be habitable structures), and associated systems and methods. Various embodiments of the technology will now be described. The following description provides specific details for a thorough understanding and enabling description of these embodiments. One skilled in the art will understand, however, that the invention may be practiced without many of these details. Additionally, some well-known structures or functions may not be shown or described in detail so as to avoid unnecessarily obscuring the relevant description of the various embodiments. Accordingly, embodiments of the present technology may include additional elements or exclude some of the elements described below with reference to
The terminology used in this description is intended to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific embodiments of the invention. Certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this detailed description section.
Where the context permits, singular or plural terms may also include the plural or singular term, respectively. Moreover, unless the word “or” is expressly limited to mean only a single item exclusive from the other items in a list of two or more items, then the use of “or” in such a list is to be interpreted as including (a) any single item in the list, (b) all the items in the list, or (c) any combination of items in the list. Further, unless otherwise specified, terms such as “attached” or “connected” are intended to include integral connections, as well as connections between physically separate components.
As used herein, the term “and/or” when used in the phrase “A and/or B” means “A, or B, or both A and B.” A similar manner of interpretation applies to the term “and/or” when used in a list of more than two terms.
Each module 120 includes usable or habitable interior space, and when multiple modules 120 are joined, they may form a combined interior space. Supporting the modules 120 on piers 110 enables building the modular structure 100 on uneven terrain while controlling (e.g., minimizing) the impact on the surrounding environment. Supporting the modules 120 on piers 110 may also facilitate using the space beneath the modular structure 100 for storage, additional usable space, or other uses. In coastal areas or other areas prone to flooding, the piers 110 provide elevation above floodwaters. Although
The module 120 may include a plurality of chords 200 (such as four chords 200), which may span the length L of the module 120. For example, in some embodiments, the chords 200 may include a first upper chord 202 oriented along the length L of the module, a first lower chord 204 oriented along the length L of the module, a second upper chord 206 positioned opposite the first upper chord 202 and oriented parallel to the first upper chord 202, and a second lower chord 208 positioned opposite the first lower chord 204 and oriented parallel to the first lower chord 204.
The module 120 may also include a plurality of rib assemblies 210, each of which extends along the width W of the module 120 between the chords 200. The module 120 may further include suitable roof panels 220 and floor panels 230. The roof panels 220 and the floor panels 230 may be supported by the rib assemblies 210 and/or the chords 200.
One or more of the chords 200 may be formed as a single integral beam or with a plurality of chord portions 250 joined together with one or more connector plates 260. For example,
Referring to
In some embodiments, the connector plate 260 carries the load from one chord portion 250a to the other chord portion 250b. Although a connector plate 260 is shown and described for connecting the chord portions 250, in some embodiments, a beam with holes similar to the holes 300 in the connector plate 260 may be used to join the chord portions 250. In some embodiments, an overall length L1 of one or more chord portions 250 may be approximately 405 inches, or other suitable dimensions.
In some embodiments, the rib assembly 500 may include one or more shear keys 530 (such as two shear keys 530, or one on each side of the rib assembly 500). The shear keys 530 may be bolted and/or welded into the rib assembly 500. The shear keys 530 project downwardly from the rib assembly 500 and are configured to engage the piers 110 (see
With additional reference to
With continued reference to
In some embodiments, the system may include a shim 610 positioned between the shear key 530 and the bottom 620 of the pocket 600. The shim 610 facilitates leveling and height adjustment to compensate for inaccuracies and/or high tolerances in the pier 110 and/or the pocket 600. Although shims 610 may not be needed if the piers 110 and pockets 600 are positioned with sufficient accuracy, in some embodiments, shims 610 of different sizes may be used in each pier 110. When the module 120 is positioned and leveled at the final installation site, filler material (such as concrete and/or grout material) may be positioned in any empty space surrounding or adjacent to the shear key 530 within the pocket 600. In some embodiments, all the empty space surrounding the shear key 530 within the pocket 600 may be filled with filler material. Accordingly, in some embodiments, anchor bolts are not needed to mount the module 120 to the piers 110.
A method of making a modular structure in accordance with embodiments of the present technology may include building the chords 200 (such as the chords 202, 204, 206, 208) and the rib assemblies 210, then connecting the elements together, then moving the assembly to a final installation site, and then penetrating/positioning the shear keys 530 into the piers 110. Optionally, the method may include leveling the module 120 using one or more shims 610 and adjusting the position of the module 120 by moving the module 120 relative to the piers 110 (which may include moving the shear keys 530 side to side within the pockets 600).
Optionally, in some embodiments, other/additional modules 120 may be positioned adjacent to the module 120 on their own piers 110. The modules 120 may be positioned and aligned relative to one another, facilitated by moving the shear keys 530 in the open space of the pocket 600 and/or by positioning one or more shims 610 under the shear keys 530 in the pockets 600. In some embodiments, methods may include filling the open space in the pockets 600 with grout, concrete, or other suitable filler material to lock modules 120 in position. Other finishing work may be performed at any suitable time, such as attachment or installation of components that render the module 120 habitable, including flooring, roofing, electrical, plumbing, and other components. In some embodiments, part of the assembly process may be performed in a factory, including some of finishing work, such as attaching roof or floor panels, electric, plumbing, etc. The modular nature of the assemblies facilitates repeatable and easily duplicated manufacturing and installation of these components.
Aspects of the embodiments of the present technology provide several advantages. For example, embodiments of the present technology provide known repeatable structures, which enables subsequent finishing trades like mechanical, plumbing, glazing, trim, electrical, etc. to rapidly add their parts with less custom fabrication. In some embodiments, construction of modules 120 configured in accordance with embodiments of the present technology may not involve any welding at the final installation site (all welding may be performed at the prefabrication site/factory).
From the foregoing, it will be appreciated that specific embodiments of the presently disclosed technology have been described herein for purposes of illustration, but that various modifications may be made without deviating from the scope of the technology. For example, steps of the methods described herein may be performed in different orders or at different times, or concurrently. Accordingly, modules 120 and modular structures 100 configured in accordance with embodiments of the present technology may include other combinations of features disclosed herein.
Certain aspects of the technology described in the context of particular embodiments may be combined or eliminated in other embodiments. Further, while advantages associated with certain embodiments of the presently disclosed technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the disclosure and associated technology can encompass other embodiments not expressly shown or described herein.
