Patent Application
20210040723
The present disclosure is generally directed to a building system, and more particularly to a building system including a plurality of interconnectable prefabricated structural components.
Modular and prefabricated construction of building is generally known as a concept. Motivations for adopting modular building technologies range from economic considerations, such as creating economies of scale for individual building components, to environmental concerns, such as sourcing sustainable materials. Other advantages of modular building construction include relatively fast erection of entire buildings and safer assembly practices due to the prefabrication of the building components.
However, current modular and/or prefabricated building systems have several shortcomings that limit more expansive use of the technology. First, many prefabricated building systems are not full universal. Second, the components of existing systems are often developed and manufactured in a piece-meal fashion, which no intended or realized aim towards universality. As a result, existing modular and/or building systems lack the ability to be reconfigured or deployed in alternative configurations to fit specific needs of a client. Finally, many existing modular and/or building systems require such a wide variety of individual component types that their use may be cost prohibitive.
In view of the foregoing, there exists a need for building systems requiring a reduced number of prefabricated structural components which can be quickly assembled in a variety of configurations. Additionally, there exists a need for methods for quickly assembling and disassembling prefabricated buildings.
Aspects of the present disclosure are generally directed to a multi-sided structure constructed from a plurality of prefabricated components consisting of fewer than 12 different prefabricated structural components. The multisided structure includes a floor assembly; a roof assembly; and a side assembly connected to the floor assembly and the roof assembly and extending between the floor assembly and the roof assembly. The floor assembly includes a plurality of the floor panels, each floor panel in direct structural connection with at least one other floor panel. The roof assembly includes a plurality of the roof panels, each roof panel in direct structural connection at least one other roof panel. The side assembly includes a plurality of the wall panels, each wall panel in direct structural connection with at least one floor panel and at least one roof panel.
In some non-limiting examples, each floor panel includes a floor surface having at least one edge and a floor engagement member extending parallel to the at least one edge of the floor surface. Each roof panel includes a roof surface having at least one edge and a roof engagement member extending parallel to the at least one edge of the floor surface.
In some non-limiting examples, at least one of the wall panels is a fixed wall panel including a fixed wall surface having a bottom edge, a top edge, and a side edge. Each fixed wall panel further includes a first engagement member extending parallel to the bottom edge, a second engagement member extending parallel to the top edge, and a third engagement member extending parallel to the side edge.
In some non-limiting examples, the first engagement member of the fixed wall panel is configured to rigidly connect to the floor engagement member of one of the floor panels, and the second engagement member of the fixed wall panel is configured to rigidly connect to the roof engagement member of one of the roof panels.
In some non-limiting examples, the floor engagement member of each floor panel includes a channel, and the first engagement member of each wall panel includes a rail configured to extend into the channel.
In some non-limiting examples, the floor engagement member of each floor panel includes a weather seal configured to engage the first engagement member of each wall panel.
In some non-limiting examples, the multi-sided structure further includes a service module having a base panel having a least one edge configured to rigidly connect to at least one of the floor panels. The service module further includes at least one of a plumbing system, a climate control system, and a sanitary system.
In some non-limiting examples, each of the floor panels further includes a duct extending below the floor surface. The duct of each of the floor panels is configured to be in fluid communication with the duct of each adjacent floor panel.
In some non-limiting examples, at least one of the floor panels, roof panels, and wall panels includes a first conduit configured to be in alignment with a second conduit of an adjacent one of the floor panels, roof panels, and wall panels.
Other aspects of the present disclosure are directed to a building system including a plurality of prefabricated structural components, wherein each of the plurality of prefabricated structural components is connectable with at least one other of the plurality of prefabricated structural components. The plurality of prefabricated structural components includes at least one floor panel, each floor panel including a floor surface having at least one edge, and a floor engagement member extending parallel to the at least one edge of the floor surface. The plurality of prefabricated structural components includes at least one fixed wall panel, each fixed wall panel including a fixed wall surface having a bottom edge, a top edge, and a side edge, a first engagement member extending parallel to the bottom edge, a second engagement member extending parallel to the top edge, and a third engagement member extending parallel to the side edge. The plurality of prefabricated structural components includes at least one roof panel, each roof panel including a roof surface having at least one edge and a roof engagement member extending parallel to the at least one edge of the floor surface.
In some non-limiting examples, the first engagement member of each fixed wall panel is configured to rigidly connect to the floor engagement member of each floor panel, and the second engagement member of each fixed wall panel is configured to rigidly connect to the roof engagement member of each roof panel.
In some non-limiting examples, the at least one fixed wall panel includes a first fixed wall panel and a second fixed wall panel, and the third engagement member of the first fixed wall panel is configured to rigidly connect to the third engagement member of the second fixed wall panel.
In some non-limiting examples, the plurality of prefabricated structural components further includes a service module. The service module includes a base panel having a least one edge configured to rigidly connect to another of the plurality of prefabricated structural components, and at least one of a plumbing system, a climate control system, and a sanitary system.
In some non-limiting examples, the plurality of prefabricated structural components further includes a sliding wall panel. The sliding wall panel includes a sliding wall surface having a bottom edge and a top edge, a first engagement member extending parallel to the bottom edge, and a second engagement member extending parallel to the top edge. The first engagement member of the sliding wall panel is configured to slidably connect to the floor engagement member of each floor panel, and the second engagement member of the sliding wall panel is configured to slidably connect to the roof engagement member of each roof panel.
In some non-limiting examples, the plurality of prefabricated structural components further includes at least one foundation pile, each foundation pile configured to be secured in a ground surface and connected to each of the floor panels.
In some non-limiting examples, each of the floor panels further includes a duct extending below the floor surface. The duct of each of the floor panels is configured to be in fluid communication with the duct of each adjacent floor panel.
In some non-limiting examples, at least one of the plurality of prefabricated structural components includes a first conduit configured to be in alignment with a second conduit of an adjacent one of the plurality of prefabricated structural components.
In some non-limiting examples, the floor engagement member of each floor panel includes a channel, and the first engagement member of each fixed wall panel includes a rail configured to extend into the channel.
In some non-limiting examples, the floor engagement member of each floor panel includes a weather seal configured to engage the first engagement member of each fixed wall panel.
In some non-limiting examples, the plurality of prefabricated structural components consists of fewer than 12 different prefabricated structural components, and complete building is constructable from only the plurality of prefabricated structural components.
In some non-limiting examples, the plurality of prefabricated structural components consists of fewer than 10 different prefabricated structural components, and a complete building is constructable from only the plurality of prefabricated structural components.
In some non-limiting examples, at least two of the floor engagement member of each floor panel, the first engagement member of each fixed wall panel, the second engagement member of each fixed wall panel, the third engagement member of each fixed wall panel, and the roof engagement member of each roof panel have a substantially identical profile.
In some non-limiting examples, the first engagement member, the second engagement member, and the third engagement member of each fixed wall panel have a substantially identical profile.
Other aspects of the present disclosure are directed to a method for constructing a building with a plurality of prefabricated structural components. The method includes arranging a plurality of floor panels on a foundation assembly, each floor panel including a floor surface having at least one edge and a floor engagement member extending parallel to the at least one edge of the floor surface. The method further includes arranging a plurality of fixed wall panels substantially perpendicularly to the plurality of floor panels, each fixed wall panel including a fixed wall surface having a bottom edge, a top edge, and a side edge, a first engagement member extending parallel to the bottom edge, a second engagement member extending parallel to the top edge, and a third engagement member extending parallel to the side edge. The method further includes arranging a plurality of roof panels spaced vertically apart from the plurality of floor panels, each roof panel including at least one edge and a roof engagement member extending parallel to the at least one edge of a floor surface of at least one floor panel of the plurality of floor panels. The method further includes connecting the first engagement member of each fixed wall panel to a corresponding floor engagement member of a floor panel of the plurality of floor panels and connecting the second engagement member of each fixed wall panel to a corresponding roof engagement member of a roof panel of the plurality of roof panels.
In some non-limiting examples, the method further includes completing the building with only the plurality of prefabricated structural components, wherein the plurality of prefabricated structural components consists of fewer than 12 distinct prefabricated components.
In accordance with other non-limiting examples, the disclosure of the present application may be characterized by one or more of the following numbered clauses:
Clause 1. A multi-sided structure constructed from a plurality of prefabricated components consisting of fewer than 12 different prefabricated structural components, the multisided structure comprising: a floor assembly; a roof assembly; and a side assembly connected to the floor assembly and the roof assembly and extending between the floor assembly and the roof assembly, wherein the floor assembly comprises a plurality of the floor panels, each floor panel in direct structural connection with at least one other floor panel, wherein the roof assembly comprises a plurality of the roof panels, each roof panel in direct structural connection at least one other roof panel, and wherein the side assembly comprises a plurality of the wall panels, each wall panel in direct structural connection with at least one floor panel and at least one roof panel.
Clause 2. The multi-sided structure according to clause 1, wherein each floor panel comprises: a floor surface having at least one edge; and a floor engagement member extending parallel to the at least one edge of the floor surface; and wherein each roof panel comprises: a roof surface having at least one edge; and a roof engagement member extending parallel to the at least one edge of the floor surface.
Clause 3. The multi-sided structure according to clause 1 or 2, wherein at least one of the wall panels is a fixed wall panel comprising: a fixed wall surface having a bottom edge, a top edge, and a side edge; a first engagement member extending parallel to the bottom edge; a second engagement member extending parallel to the top edge; and a third engagement member extending parallel to the side edge.
Clause 4. The multi-sided structure according to any of clauses 1-3, wherein the first engagement member of the fixed wall panel is configured to rigidly connect to the floor engagement member of one of the floor panels, and wherein the second engagement member of the fixed wall panel is configured to rigidly connect to the roof engagement member of one of the roof panels.
Clause 5. The multi-sided structure according to any of clauses 1-4, wherein the floor engagement member of each floor panel comprises a channel, and wherein the first engagement member of each wall panel comprises a rail configured to extend into the channel.
Clause 6. The multi-sided structure according to any of clauses 1-5, wherein the floor engagement member of each floor panel comprises a weather seal configured to engage the first engagement member of each wall panel.
Clause 7. The multi-sided structure according to any of clauses 1-6, further comprising a service module, the service module comprising: a base panel having a least one edge configured to rigidly connect to at least one of the floor panels; and at least one of a plumbing system, a climate control system, and a sanitary system.
Clause 8. The multi-sided structure according to any of clauses 1-7, wherein each of the floor panels further comprises a duct extending below the floor surface, and wherein the duct of each of the floor panels is configured to be in fluid communication with the duct of each adjacent floor panel.
Clause 9. The multi-sided structure according to any of clauses 1-8, wherein at least one of the floor panels, roof panels, and wall panels comprises a first conduit configured to be in alignment with a second conduit of an adjacent one of the floor panels, roof panels, and wall panels.
Clause 10. A building system comprising a plurality of prefabricated structural components, wherein each of the plurality of prefabricated structural components is connectable with at least one other of the plurality of prefabricated structural components, the plurality of prefabricated structural components comprising: (a) at least one floor panel, each floor panel comprising: (i) a floor surface having at least one edge; and (ii) a floor engagement member extending parallel to the at least one edge of the floor surface; (b) at least one fixed wall panel, each fixed wall panel comprising: (i) a fixed wall surface having a bottom edge, a top edge, and a side edge; (ii) a first engagement member extending parallel to the bottom edge; (iii) a second engagement member extending parallel to the top edge; and (iii) a third engagement member extending parallel to the side edge; and (c) at least one roof panel, each roof panel comprising: (i) a roof surface having at least one edge; and (ii) a roof engagement member extending parallel to the at least one edge of the floor surface.
Clause 11. The building system according to clause 10, wherein the first engagement member of each fixed wall panel is configured to rigidly connect to the floor engagement member of each floor panel, and wherein the second engagement member of each fixed wall panel is configured to rigidly connect to the roof engagement member of each roof panel.
Clause 12. The building system according to clause 10 or 11, wherein the at least one fixed wall panel comprises a first fixed wall panel and a second fixed wall panel, and wherein the third engagement member of the first fixed wall panel is configured to rigidly connect to the third engagement member of the second fixed wall panel.
Clause 13. The building system according to any of clauses 10-12, wherein the plurality of prefabricated structural components further comprises a service module, the service module comprising: a base panel having a least one edge configured to rigidly connect to another of the plurality of prefabricated structural components; and at least one of a plumbing system, a climate control system, and a sanitary system.
Clause 14. The building system according to any of clauses 10-13, wherein the plurality of prefabricated structural components further comprises a sliding wall panel, the sliding wall panel comprising: a sliding wall surface having a bottom edge and a top edge; a first engagement member extending parallel to the bottom edge; and a second engagement member extending parallel to the top edge, wherein the first engagement member of the sliding wall panel is configured to slidably connect to the floor engagement member of each floor panel, and wherein the second engagement member of the sliding wall panel is configured to slidably connect to the roof engagement member of each roof panel.
Clause 15. The building system according to any of clauses 10-14, wherein the plurality of prefabricated structural components further comprises at least one foundation pile, each foundation pile configured to be secured in a ground surface and connected to each of the floor panels.
Clause 16. The building system according to any of clauses 10-15, wherein each of the floor panels further comprises a duct extending below the floor surface, and wherein the duct of each of the floor panels is configured to be in fluid communication with the duct of each adjacent floor panel.
Clause 17. The building system according to any of clauses 10-16, wherein at least one of the plurality of prefabricated structural components comprises a first conduit configured to be in alignment with a second conduit of an adjacent one of the plurality of prefabricated structural components.
Clause 18. The building system according to any of clauses 10-17, wherein the floor engagement member of each floor panel comprises a channel, and wherein the first engagement member of each fixed wall panel comprises a rail configured to extend into the channel.
Clause 19. The building system according to any of clauses 10-18, wherein the floor engagement member of each floor panel comprises a weather seal configured to engage the first engagement member of each fixed wall panel.
Clause 20. The building system according to any of clauses 10-19, wherein the plurality of prefabricated structural components consists of fewer than 12 different prefabricated structural components, and wherein a complete building is constructable from only the plurality of prefabricated structural components.
Clause 21. The building system according to any of clauses 10-20, wherein the plurality of prefabricated structural components consists of fewer than 10 different prefabricated structural components, and wherein a complete building is constructable from only the plurality of prefabricated structural components.
Clause 22. The building system according to any of clauses 10-21, wherein at least two of the floor engagement member of each floor panel, the first engagement member of each fixed wall panel, the second engagement member of each fixed wall panel, the third engagement member of each fixed wall panel, and the roof engagement member of each roof panel have a substantially identical profile.
Clause 23. The building system according to any of clauses 10-22, wherein the first engagement member, the second engagement member, and the third engagement member of each fixed wall panel have a substantially identical profile.
Clause 24. A method for constructing a building with a plurality of prefabricated structural components, comprising: arranging a plurality of floor panels on a foundation assembly, each floor panel comprising a floor surface having at least one edge and a floor engagement member extending parallel to the at least one edge of the floor surface; arranging a plurality of fixed wall panels substantially perpendicularly to the plurality of floor panels, each fixed wall panel comprising a fixed wall surface having a bottom edge, a top edge, and a side edge, a first engagement member extending parallel to the bottom edge, a second engagement member extending parallel to the top edge, and a third engagement member extending parallel to the side edge; arranging a plurality of roof panels spaced vertically apart from the plurality of floor panels, each roof panel comprising at least one edge and a roof engagement member extending parallel to the at least one edge of a floor surface of at least one floor panel of the plurality of floor panels; connecting the first engagement member of each fixed wall panel to a corresponding floor engagement member of a floor panel of the plurality of floor panels; and connecting the second engagement member of each fixed wall panel to a corresponding roof engagement member of a roof panel of the plurality of roof panels.
Clause 25. The method according to clause 24, further comprising completing the building with only the plurality of prefabricated structural components, wherein the plurality of prefabricated structural components consists of fewer than 12 distinct prefabricated components.
These and other features and characteristics of building systems, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the disclosure. As used in the specification and claims, the singular forms of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.
For purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “lateral”, “longitudinal”, and derivatives thereof shall relate to the disclosed apparatus as it is oriented in the figures. However, it is to be understood that the apparatus of the present disclosure may assume alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific systems and processes illustrated in the attached drawings and described in the following specification are simply exemplary examples of the apparatus disclosed herein. Hence, specific dimensions and other physical characteristics related to the examples disclosed herein are not to be considered as limiting.
As used herein, the term “associated with”, when used in reference to multiple features or structures, means that the multiple features or structures are in contact with, touching, directly connected to, indirectly connected to, adhered to, or integrally formed with one another.
As used herein, the term “at least one of” is synonymous with “one or more of”. For example, the phrase “at least one of A, B, and C” means any one of A, B, and C, or any combination of any two or more of A, B, and C. For example, “at least one of A, B, and C” includes one or more of A alone; or one or more B alone; or one or more of C alone; or one or more of A and one or more of B; or one or more of A and one or more of C; or one or more of B and one or more of C; or one or more of all of A, B, and C. Similarly, as used herein, the term “at least two of” is synonymous with “two or more of”. For example, the phrase “at least two of D, E, and F” means any combination of any two or more of D, E, and F. For example, “at least two of D, E, and F” includes one or more of D and one or more of E; or one or more of D and one or more of F; or one or more of E and one or more of F; or one or more of all of D, E, and F.
As used herein, the terms “direct structural connection”, “directly structurally connected to”, and derivatives thereof define a relationship between two or more components in which the two or more components meet at a junction, and at least one of the components applies a static or dynamic load to the other of the components without the load being first transferred through an intervening structural member. The two or more components may be secured to one another in any suitable manner. For example, a surface of one component may abut a surface of another component. Alternatively or additionally, a key or rail of one component may fit into a groove or channel of another component. Mechanical fasteners such as screws, bolts, pins, rivets, or the like may be used to prevent displacement of the two of more components relative to each other. In other examples, non-structural members, such as seals, alignment shims, or spacers may be provided between the two or more components, such that the two or more components are not in direct physical contact.
As used herein, the term “prefabricate” means to manufacture an assembly or sub-assembly of a structure at a location remote from the location at which the structure is assembled. The term “prefabricated” describes a component manufactured in this manner. For example, a wall segment of a building may be prefabricated from various raw materials at a remote location, and the prefabricated wall segment may then be transported to the assembly site of the building. In this manner, the wall segment need not be constructed from raw materials at the assembly site. The terms “prefabricated” and “modular” may be used interchangeably herein.
As used herein, the term “prefabricated structural component” means an element used in a building that forms at least part of a floor, roof, or wall surface of the building. A prefabricated structural component must be directly structurally connectable with at least one other prefabricated structural component.
As use herein, the terms “perpendicular” and “substantially perpendicular”, unless explicitly stated to the contrary, mean an angle between two or more components of 90° plus or minus 10°.
As used herein, the term “exterior” is used to describe components component having at least a portion that is suitable for use in an outside environment unprotected from weather and elements. However, it should be understood that components referred to as “exterior” may also be used in interior applications, unless explicitly noted to the contrary.
Aspects of the present disclosure are generally directed to building systems including a plurality of prefabricated structural components, and to a building constructed from a plurality of prefabricated structural components.
The floor assembly 10 may be constructed from one or more prefabricated floor panels 110 of the building system of the present disclosure. Similarly, the roof assembly 20 may be constructed from one or more prefabricated roof panels 210 of the building system of the present disclosure. Similarly, each of the exterior wall assemblies 30 may be constructed from one or more prefabricated exterior wall panels 310 of the building system of the present disclosure. The prefabricated floor panels 110, prefabricated roof panels 210, and prefabricated exterior wall panels 310 of the building system will be described later in greater detail. However, for the purposes of describing the buildings 1000 in general, it is noted that the prefabricated floor panels 110, prefabricated roof panels 210, and prefabricated exterior wall panels 310 are among a plurality of prefabricated structural component types which at least partially make up the building system of the present disclosure. Each of the prefabricated structural components of the building system is connectable with at least one other prefabricated structural component in order to construct the building 1000. For example, in the buildings shown in
As may be further appreciated from the buildings 1000 of
With continued reference to
With continued reference to
Referring now to
The buildings 1000 shown in
Having generally described various examples of buildings 1000, 1000a, 1000b constructed from the building system of the present disclosure, the individual prefabricated structural components of the building system will now be described in detail. As described above, prefabricated structural components of the building system may include at least floor panels 110, roof panels 210, exterior wall panels 310, foundation support columns 142, sliding interior wall panels 170, and service modules 190. Out of these individual prefabricated structural components, the buildings 1000 described with reference to
Referring first to
Referring now to
The edge connection members 1130 may define or include a plurality of structural features serving as conduits for electrical cable and engagement members for connecting other prefabricated structural components. The foundation groove or recess 1132 may be defined in an underside of the edge connection members 1130 and serve as an engagement member for direct structural connection with one or more support columns 142, as discussed above. One or more floor engagement members 1134 may extend along a top side of the edge connection members 1130 and provide direct structural connection to one or more interior or exterior wall panels. In some examples, the floor engagement members 1134 may include a plurality of channels extending parallel to the edges of the shell 1110. The plurality of channels may include multiple profiles suitable for connection to different types of walls. For example, one portion of the floor engagement member 1134 may be connectable to an exterior fixed wall panel 130, another portion of the floor engagement member 1134 may be connectable to a cabinet wall component 150, another portion of the floor engagement member 1134 may be connectable to a sliding exterior wall panel 160, and another portion of the floor engagement member 1134 may be connectable to an interior sliding wall panel 170.
The floor engagement members 1134 may extend the entire length of each edge of the floor panel 110, such that the floor engagement members 1134 form a continuous structure with the floor engagement members 1134 of adjacent floor panels 110. Covers sitting substantially flush with the interior panel face 1114 may be installed over portions of the floor engagement members 1134 to which no other prefabricated structural components are connected to provide a smooth floor surface.
The edge connection members 1130 may further define one or more cable channels 1136, which may extend parallel to the floor engagement members 1134. The cable channels 1136 may be recessed below the interior panel face 1114 and may be used as a conduit for routing electrical, fiber optic, coaxial, Ethernet, and other types of cable to terminals in the floor panel 110, or through the floor panel 110 to adjacent prefabricated structural components. Covers may be installed over the cable channels 1136 substantially flush with the interior panel face 1114 after the various cables are installed in the cable channels 1136. Further details of the cable channels 1136 will be described later with reference to
In some examples, the edge connection members 1130 may further include one or more weather seals for insulating the connection between the floor panel 110 and any adjacent prefabricated structural components. The weather seals may be located adjacent the floor engagement members 1134 and/or the cable channels 1136. The one or more weather seals may extend the entire length of each edge of the floor panel 110, such that the weather seals of adjacent floor panels 110 form a continuous weather seal with one another.
In some examples, the edge connection members 1130 may further include one or more weather seal engagement surfaces for abutting a weather seal provided on an adjacent prefabricated structural component. In some examples, the weather seal engagement surfaces may be located adjacent the floor engagement members 1134 and/or the cable channels 1136. In other examples, the weather seal engagement surfaces may be included in the floor engagement members 1134 and/or the cable channels 1136. The weather seal engagement surfaces may extend the entire length of each edge of the floor panel 110, such that the weather seal engagement surfaces of adjacent floor panels 110 form a continuous weather seal engagement surface with one another. Further details of the weather seal and weather seal engagement surfaces will be described later with reference to
One or more ducts 1122 may extend through the core 1120 of the floor panel 110 to facilitate flow of air to the floor panel 110 and to adjacent prefabricated structural components. The edge connection members 1130 and/or the interior panel face 1114 may have an opening in fluid communication with the ducts 1122 such that air can be delivered to and returned from the area above the interior panel face 1114 via the ducts 1122. The one or more ducts may extend the entire length of each edge of the floor panel 110, such that the ducts 1122 of each floor panel 110 form a continuous fluid conduit with the ducts 1122 of adjacent floor panels 110.
Materials for the components of the floor panels 110 may be selected to optimize strength, manufacturing cost, environmental sustainability, heat and sound insulation, fire resistance, and other desirable characteristics of residential and/or commercial buildings. The exterior panel face 1112, which functions as a moisture barrier and structural tension member, may be made from a polymer or metal sheet. The interior panel face 1114, which functions as a soft walking and living surface, may be made from easily maintainable vinyl, rubber, or neoprene sheet. The edge connection members 1130, which bear substantially all of the load of the prefabricated structural components connected to the floor panel 110, may be made from a relatively high strength material such as extruded aluminum. The edge connection members 1130 may be connected to the exterior panel face 1112 and the interior panel face 1114 via mechanical fasteners, adhesives, welds, or the like. The core 1120, which functions as a heat insulator, acoustic barrier, and structural compression member, may be made from a foam such as expanded polystyrene (EPS), extruded polystyrene (XPS), or rigid polyurethane. During manufacture of the core 1120, steam may be passed through the ducts 1122 to expand and cure the polystyrene foam forming the core 1120. The foam of the core 1120 may extend substantially uninterrupted along the exterior panel face 1112 and/or the interior panel face 1114 such that the floor panel 110 has continuous insulation and avoids heat losses through non-insulating framing members. It is to be understood that the various material described herein for use in any component are solely exemplary and not to be construed as limiting.
Referring now to
The edge connection members 1330 may define a plurality of engagement members for connecting other prefabricated structural components. A portion of the edge connection members 1330 extending parallel to a bottom edge of the fixed wall panel 130 may include or define a first engagement member 1332 configured for direct structural connection with the floor engagement member 1134 of an adjacent floor panel 110. A portion of the edge connection members 1330 extending parallel to a vertical edge of the fixed wall panel 130 may include or define a second engagement member 1334. The second engagement members 1334 of adjacently arranged fixed wall panels 130 may be configured for direct structural connection with one another. A portion of the edge connection members 1330 extending parallel to a top edge of the fixed wall panel 130 may include or define a third engagement member 1336 for direct structural connection with a roof engagement member 1232 of and adjacent roof panel 210 (See
In some examples, the portions of the edge connection members 1330 extending parallel to bottom edge, vertical side edges, and top edge of the fixed wall panel 130 may further define one or more one or more cable channels (not shown) similar to the cable channels 1136 of the floor panel 110. The cable channels of the fixed wall panel 130 may be used for routing electrical or other types of cable to terminal in the fixed wall panel 130, or through the fixed wall panel 130 to adjacent prefabricated structural components.
In some examples, the edge connection members 1330 may further include one or more weather seals for insulating the connection between the fixed wall panel 130 and any adjacent prefabricated structural components. The weather seals may be located adjacent any one or more of the engagement members 1332, 1334, 1336 and/or the cable channels. The one or more weather seals may extend the entire length of an edge of the fixed wall panel 130, such that the weather seals of adjacent fixed wall panels 130 form a continuous weather seal with one another.
In some examples, the edge connection members 1330 may further include one or more weather seal engagement surfaces for abutting a weather seal provided on an adjacent prefabricated structural component. In some examples, the weather seal engagement surfaces may be located adjacent any one or more of the engagement members 1332, 1334, 1336 and/or the cable channels. In other examples, the weather seal engagement surfaces may be included in any one or more of the engagement members 1332, 1334, 1336 and/or the cable channels. The weather seal engagement surfaces may extend the entire length of an edge of the fixed wall panel 130, such that the weather seal engagement surfaces of adjacent fixed wall panels 130 form a continuous weather seal engagement surface with one another.
Material selection for the components of the prefabricated fixed wall panel 130 may be similar to that of the floor panels 110. The exterior panel face 1312, which may function as a moisture barrier, structural tension member, exterior face of the building 1000, and/or impact barrier, may be made from a fiber cement panel or fiber-reinforced plastic (FRP). The interior panel face 1314, which functions as an interior wall surface, may be made from easily maintainable vinyl, rubber, or neoprene sheet. The edge connection members 1330 may be made from a relatively high strength material such as extruded aluminum. The edge connection members 1330 may be connected to the exterior panel face 1312 and the interior panel face 1314 via mechanical fasteners, adhesives, welds, or the like. The core 1320, which functions as a heat insulator, acoustic barrier, and structural compression member, may be made from a foam such as expanded polystyrene (EPS), extruded polystyrene (XPS), or rigid polyurethane. The foam of the core 1320 may extend substantially uninterrupted along the exterior panel face 1312 and/or the interior panel face 1314 such that the fixed wall panel 130 has continuous insulation and avoids heat losses through non-insulating framing members.
Referring now to
The internal working area 1550 may include integral storage receptacles such as shelving and cabinetry, or the internal working area 1550 may include supports for mounting integral storage receptacles after the cabinet wall component 150 has been assembled with other prefabricated structural components to construct the building 1000.
The edge connection members 1530 may define a plurality of engagement members for connecting other prefabricated structural components. A portion of the edge connection members 1530 extending parallel to a bottom edge of the cabinet wall component 150 may include or define a first engagement member 1532 configured for direct structural connection with the floor engagement member 1134 of an adjacent floor panel 110. A portion of the edge connection members 1530 extending parallel to a vertical edge of end caps 1560 of the cabinet wall component 150 may include or define a second engagement member 1534. The second engagement members 1534 of adjacently arranged cabinet wall components 150 may be configured for direct structural connection one another. A portion of the edge connection members 1530 extending parallel to a top edge of the cabinet wall component 150 may include or define a third engagement member 1536 for direct structural connection with a roof engagement member 1232 of and adjacent roof panel 210 (See
In some examples, the first and third engagement members 1532, 1536 of the cabinet wall component 150 may by be configured to engage only a portion of the corresponding floor engagement member 1134 of an adjacent floor panel 110 and the roof engagement member 1232 of an adjacent roof panel 210. The unengaged portions of the corresponding floor engagement member 1134 and the roof engagement member 1232 may then be used for connecting internal sliding cabinet doors 180, as will be described later in connection with
In some examples, the portions of the edge connection members 1530 extending parallel to bottom edge, vertical side edges, and top edge of the cabinet wall component 150 may further define one or more one or more cable channels (not shown) similar to the cable channels 1136 of the floor panel 110. The cable channels of the cabinet wall component 150 may be used for routing electrical or other types of cable to terminal in the cabinet wall component 150, or through the cabinet wall component 150 to adjacent prefabricated structural components.
In some examples, the edge connection members 1530 may further include one or more weather seals for insulating the connection between the cabinet wall component 150 and any adjacent prefabricated structural components. The weather seals may be located adjacent any one or more of the engagement members 1532, 1534, 1536 and/or the cable channels. The one or more weather seals may extend the entire length of an edge of the cabinet wall component 150, such that the weather seals of adjacent cabinet wall component 150 form a continuous weather seal with one another.
In some examples, the edge connection members 1530 may further include one or more weather seal engagement surfaces for abutting a weather seal provided on an adjacent prefabricated structural component. In some examples, the weather seal engagement surfaces may be located adjacent any one or more of the engagement members 1532, 1534, 1536 and/or the cable channels. In other examples, the weather seal engagement surfaces may be included in any one or more of the engagement members 1532, 1534, 1536 and/or the cable channels. The weather seal engagement surfaces may extend the entire length of an edge of the cabinet wall component 150, such that the weather seal engagement surfaces of adjacent cabinet wall component 150 form a continuous weather seal engagement surface with one another.
Material selection for components of the cabinet wall component 150 may be similar to that of like components of the fixed wall panel 130.
Referring now to
One or more of the first, second, and third engagement members 1632, 1634, 1636 may further include a seal or sealing surface configured to engage a corresponding seal or sealing surface of an adjacent prefabricated structural component. Additionally one or more of the subpanels 1610 may include a seal or sealing surface configured to engage a corresponding seal or sealing surface of others of the subpanels 1610. In some examples, the seals may be provided on stiles 1620 of the subpanels 1610.
The one or more subpanels 1610 may at least partially overlap and may be slidable relative to one another in a horizontal direction, allowing an opening to be created between the subpanels 1610. In this manner, the exterior sliding wall panel 160 may function as a window or door. The stiles 1620 of the subpanels 1610 may be interlocking to provide a secure and insulated connection between the subpanels 1610. In some examples, the stiles 1620 may be interlocking in multiple positions allowing the subpanels 1610 to be arranged in horizontal alignment as shown in
The subpanels 1610 may be made from various materials depending on desired characteristics, such as opacity. Steam cured calcium silicate may be used for opaque subpanels 1610, thermosetting plastics may be used for translucent subpanels 1610, and thermosetting plastic or glass may be used for transparent subpanels 1610. In some examples, different materials may be used for the different subpanels 1610 of a single sliding exterior wall panel 160. The wheels, spherical rollers, or the like may be mechanically secured directly to the subpanels 1610 or, alternatively, secured indirectly to the subpanels 1610 via a mounting frame or the like.
Referring now to
The edge connection members 1230 may define or include one or more roof engagement members 1232 extending along an underside of the edge connection members 1230 and provide direct structural connection to one or more exterior or interior wall panels. In some examples, the roof engagement members 1232 may include a plurality of channels extending parallel to the edges of the shell 1210. The plurality of channels may include multiple profiles suitable for connection to different types of walls. For example, one portion of the roof engagement member 1232 may be connectable to an exterior fixed wall panel 130, another portion of the roof engagement member 1232 may be connectable to a cabinet wall component 150, another portion of the roof engagement member 1232 may be connectable to a sliding exterior wall panel 160, and another portion of the roof engagement member 1232 may be connectable to an interior sliding wall panel 170.
The roof engagement members 1232 may extend the entire length of each edge of the roof panel 210, such that the roof engagement members 1234 form a continuous structure with the roof engagement members 1232 of adjacent roof panels 210. In some examples, the profile of the roof engagement members 1232 may be substantially identical to the profile of the floor engagement members 1134 of the floor panels 110 to reduce the number of component materials necessary to fabricate the floor panels 110 and the roof panels 210. Additionally, identical roof engagement members 1232 and floor engagement members 1134 may allow the exterior and interior wall panel to be connected in multiple orientations between pairs of floor panels 110 and roof panels 210.
The edge connection members 1230 may further define one or more cable channels 1236, which may extend parallel to the roof engagement members 1234. The cable channels 1236 may be recessed below the interior panel face 1214 and may be used as a conduit for routing electrical, fiber optic, coaxial, Ethernet, and other types of cable to terminals in the roof panel 210, or through the roof panel 210 to adjacent prefabricated structural components. Covers may be installed over the cable channels 1236 substantially flush with the interior panel face 1214 after the various cables are installed in the cable channels 1236.
In some examples, the edge connection members 1230 may further include one or more weather seals for insulating the connection between the roof panel 210 and any adjacent prefabricated structural components. The weather seals may be located adjacent the roof engagement members 1234 and/or the cable channels 1236. The one or more weather seals may extend the entire length of each edge of the roof panel 210, such that the weather seals of adjacent roof panels 210 form a continuous weather seal with one another.
In some examples, the edge connection members 1230 may further include one or more weather seal engagement surfaces for abutting a weather seal provided on an adjacent prefabricated structural component. In some examples, the weather seal engagement surfaces may be located adjacent the roof engagement members 1234 and/or the cable channels 1236. In other examples, the weather seal engagement surfaces may be included in the roof engagement members 1234 and/or the cable channels 1236. The weather seal engagement surfaces may extend the entire length of each edge of the roof panel 210, such that the weather seal engagement surfaces of adjacent roof panels 210 form a continuous weather seal engagement surface with one another.
One or more ducts 1222 may extend through the core 1220 of the roof panel 210 to facilitate flow of air to the roof panel 210 and to adjacent prefabricated structural components. The edge connection members 1230 and/or the interior panel face 1214 may have an opening in fluid communication with the ducts 1222 such air can be delivered to and returned from the area below the interior panel face 1214 via the ducts 1122. The one or more ducts may extend the entire length of each edge of the roof panel 210, such that the ducts 1222 of each roof panel 210 form a continuous fluid conduit with the ducts 1222 of adjacent roof panels 210.
Materials for the components of the floor panels 210 may be substantially identical to the materials of like components of the floor panels 210.
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The service module may include bathroom, kitchen, and/or utility areas. In some examples, the service module 190 may include a central heating and/or cooling unit 1950, a refrigerator 1952, a laundry washer 1954, a laundry dryer 1956, a dishwasher 1958, a stove 1960, a sink 1962, and a bathroom 1964. Other examples of the service module may include more or less fixtures according to the intended purpose of the building 1000.
The service module 190 may be configured for direct structural connection with adjacent prefabricated structural components in a manner similar to that described above in connection with the floor panels 110, roof panels 210, exterior wall panels 310, and sliding interior wall panels 170.
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Other aspects of the present disclosure are directed to a method for constructing one or more buildings 1000 from a plurality of prefabricated structural components, namely the prefabricated structural components discussed above with respect to
At step 7100, the configuration of the building 1000 is designed. Step 7100 includes choosing a layout of the building 1000 and selecting the types and quantities of prefabricated structural components necessary to achieve that layout. For example, a designer may choose characteristics of the building 1000 such as overall dimensions, floor plans, subdivision of interior spaces, location of building utilities, etc. and choose prefabricated structural components to conform to the chosen characteristics of the building 1000. In some examples, step 7100 may be performed with the assistance of a computer to provide a virtual simulation of the building 1000 based on inputs of the designer. For example, the designer may input, via an input device of the computer, some or all of the characteristics of the building 1000 listed above. A processor of the computer may receive the inputs and execute program instructions stored in a transitory or non-transitory memory which cause the processor to generate output data, such as the types and quantities of prefabricated structural components necessary to construct the building 1000. The processor may generate and display a virtual model, construction plans, and/or a bill of materials for the building 1000. In some examples, step 7100 may be further automated with the computer such that the computer, via the program instructions, at least partially chooses or modifies the configuration of the building 1000 to optimize factors such as component costs, environmental impact, energy efficiency, etc.
At step 7200, after the building 1000 is designed, a foundation is installed based on the building design. As shown in
At step 7300, the service modules 190 may be installed as shown in
At step 7400, the floor assembly 10 is constructed by attaching the floor panels 110 to the foundation. As shown in
At step 7500, the exterior wall assemblies 30 may be constructed by attaching the exterior wall panels 310 to the floor panels 110. Concurrently with or after construction of the exterior wall assemblies 30, the sliding interior wall panels 170 and sliding cabinet doors 180 may be installed at step 7600.
At step 7700, the roof assembly 20 may be constructed by attaching the roof panels 210 to the prefabricated structural components already installed. As shown in
Throughout steps 7300-7700, the weather seals 600 may be installed between the engagement members of adjacent prefabricated structural components, as discussed above in connection with
At step 7800, the piping 500 may be routed through the ducts the prefabricated structural components as discussed above in connection with
While several examples of a building system, a building, and a method for constructing a building are shown in the accompanying figures and described in detail hereinabove, other examples will be apparent to and readily made by those skilled in the art without departing from the scope and spirit of the present disclosure. For example, it is to be understood that aspects of the various examples described hereinabove may be combined with aspects of other examples while still falling within the scope of the present disclosure. Accordingly, the foregoing description is intended to be illustrative rather than restrictive. The assembly of the present disclosure described hereinabove is defined by the appended claims, and all changes to the disclosed assembly that fall within the meaning and range of equivalency of the claims are to be embraced within their scope.
This application claims the benefit of U.S. Provisional Patent Application No. 62/638,451, filed Mar. 5, 2018, the disclosure of which is hereby incorporated by reference in its entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2019/020668 | 3/5/2019 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62638451 | Mar 2018 | US |
