APPARATUS AND SYSTEMS RELATED TO MODULAR CONSTRUCTION

Abstract

Systems and apparatuses related to modular construction of various structures are provided herein. The systems and apparatuses described can include a plurality of frame members, insert tube members, and fastening plates to join a plurality of modular structures.

Description

PRIORITY

This application claims priority to U.S. Provisional Application No. 62/583,174, filed on Nov. 8, 2017, which is incorporated herein by reference in its entirety.

FIELD

Described herein are apparatuses and systems related to modular construction. In some aspects, the apparatuses and systems described herein relate to construction of a modular structure comprising steel.

BACKGROUND

Construction of large buildings or structures are often subject to delays and increased costs due to factors commonly outside of a builder's or developer's control. Weather, availability of labor, cost of labor, and other factors introduce much variability into the building process and construction timeline. Also, buildings that have a large footprint can disrupt adjacent properties and traffic. Speed of construction and structural integrity of the building are two important considerations for any new construction project.

In some cases, many large buildings and projects, for example, hotels, dormitories, or apartment complexes, generally have a common floorplan. This common floorplan may be carried throughout a particular floor and/or throughout the different levels in the building. However, even a building with common floorplan faces many of the same obstacles noted above. Thus, improved systems and apparatuses for building different structures is desired.

SUMMARY

This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification, any or all drawings and each claim. The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary.

In some embodiments, a modular structure system can comprise a first corner frame member comprising at least one flange having at least one opening, a first insert tube member, and an exterior surface defining a first exterior opening; a second corner frame member comprising at least one flange having at least one opening, a second insert tube member, and an exterior surface defining a second exterior opening; and a fastening plate defining a first fastening plate opening and a second fastening plate opening. In some such embodiments, the first fastening plate opening is aligned with the first exterior opening of the first corner frame member such that a first fastener can be positioned through both the first fastening plate opening and the first exterior opening of the first corner frame member and the second fastening plate opening is aligned with the second exterior opening of the second corner frame member such that a second fastener can be positioned through both the second fastening plate opening and the second exterior opening of the second corner frame member. The fastening plate can serve to attach the first corner frame member and the second corner frame member. In some embodiments, the first corner member is in a first modular room and the second corner member is in a second modular room. Thus, once the fastening plate is attached to both the first corner member and the second corner member, the first modular room and the second modular room are positioned and secured adjacent to each other.

In some embodiments, a modular structure comprising a first modular room having a first corner frame member comprising at least one flange having at least one opening, a first insert tube member, and an exterior surface defining a first exterior opening; and a second modular room having a second corner frame member comprising at least one flange having at least one opening, a second insert tube member, and an exterior surface defining a second exterior opening; and a fastening plate defining a first fastening plate opening and a second fastening plate opening are described herein. In some such embodiments, the first fastening plate opening is aligned with the first exterior opening of the first corner frame member such that a first fastener can be positioned through both the first fastening plate opening and the first exterior opening of the first corner frame member and the second fastening plate opening is aligned with the second exterior opening of the second corner frame member such that a second fastener can be positioned through both the second fastening plate opening and the second exterior opening of the second corner frame member. This arrangement results in the first modular room being positioned adjacent to and attached to the second modular room.

The details of one or more embodiments are set forth in the description below. Other features, objects, and advantages will be apparent from the description and from the claims.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 shows a portion of a modular structure according to one embodiment of the present invention.

FIG. 2 shows a top plan view of a schematic showing a plurality of modular structures according to one embodiment of the present invention.

FIG. 3A shows a corner frame member according to one embodiment of the present invention.

FIG. 3B shows a cross-sectional view of a corner frame member along the B-B plane of the corner frame member shown in FIG. 3A.

FIG. 4 shows a top view of a cross-section of a portion of a modular structure having a plurality of corner frame members according to one embodiment of the present invention.

FIG. 5 shows a top view of a cross-section of a portion of a modular structure having a plurality of corner frame members according to one embodiment of the present invention.

FIG. 6A shows a portion of a frame member and an insert tube member according to one embodiment of the present invention.

FIG. 6B shows a portion of a frame member and an insert tube member according to one embodiment of the present invention

FIG. 7 shows a top view of a cross section of a portion of a modular structure having a plurality of intermediate support members according to one embodiment of the present invention.

FIG. 8 shows a side view of a portion of a frame member and an insert tube member according to one embodiment of the present invention.

FIG. 9 shows a modular structure comprising a plurality of modular rooms.

DETAILED DESCRIPTION

Provided herein are systems and apparatus that can be used for construction of modular structures. For example, the present invention can be used to facilitate the construction of certain structures in a first location to build a plurality of modular rooms, and then assembling or joining the plurality of modular rooms in a second location into one cohesive structure.

Certain benefits can result from assembling a modular room in a first location. For example, the construction of a modular room can be in a location remote of the second location, i.e., the actual final location of the building. In some such cases, the first location can be in a climate-controlled location to avoid adverse effects of weather, in a location with a skilled workforce, and/or in a location where labor costs may be lower. Also in some such cases, the construction of the modular rooms in a first location allows for work to be completed on the actual rooms simultaneously as work at the second location occurs. For example, while different site work such as grading and pouring foundations are being completed at the second location, simultaneous building of the actual rooms can be occurring at the first location.

While some of the advantages may be known in the art, problems with modular construction and the size and height of structures must be overcome. For example, limitations associated with the materials of what certain structures are made of can limit the size of the final assembled modular structure. For example, a modular structure relying on timber or wood cannot generally exceed four stories or levels often because of structural considerations or other code restrictions such as fire hazard-related regulations. The present invention addresses many of these issues in developing systems and apparatuses to make modular structures. For example, embodiments described herein can be comprised of steel and provide systems and methods for joining a plurality of modular rooms. Embodiments according to the invention described herein can avoid many of the issues associated with conventional modular structures. For example, systems and apparatus described herein can allow the height of a building to increase from 4 levels with timber modular, to up to 10 levels using metal and connections described herein. Also, using systems and apparatus described herein can increase the speed of construction up to 40 to 50% quicker than traditional construction methods, and the cost can be typically 10 to 15% less expensive than traditional construction. Thus, in some embodiments, projects previously not viable can now become economically viable using systems and apparatuses described herein.

In some embodiments, a modular structure system can comprise a first corner frame member comprising at least one flange having at least one opening, a first insert tube member, and an exterior surface defining a first exterior opening; a second corner frame member comprising at least one flange having at least one opening, a second insert tube member, and an exterior surface defining a second exterior opening; and a fastening plate defining a first fastening plate opening and a second fastening plate opening. In some such embodiments, the first fastening plate opening is aligned with the first exterior opening of the first corner frame member such that a first fastener can be positioned through both the first fastening plate opening and the first exterior opening of the first corner frame member and the second fastening plate opening is aligned with the second exterior opening of the second corner frame member such that a second fastener can be positioned through both the second fastening plate opening and the second exterior opening of the second corner frame member. The fastening plate can serve to attach the first corner frame member and the second corner frame member. In some embodiments, the first corner member is in a first modular room and the second corner member is in a second modular room. Thus, once the fastening plate is attached to both the first corner member and the second corner member, the first modular room and the second modular room are positioned and secured adjacent to each other.

In some embodiments, the first fastening plate may have more than two openings. For example, in some cases, the exterior surface of the first corner frame member defines a third exterior opening, the exterior surface of the second corner frame member defines a fourth exterior opening, and the fastening plate defines a third fastening plate opening and a fourth fastening plate opening. In some such embodiments, the third fastening plate opening is aligned with the third exterior opening of the first corner frame member such that a third fastener can be positioned through both the third fastening plate opening and the third exterior opening of the first corner frame member and the fourth fastening plate opening is aligned with the fourth exterior opening of the second corner frame member such that a fourth fastener can be positioned through both the fourth fastening plate opening and the fourth exterior opening of the second corner frame member.

In some cases, the at least one flange of the first corner frame member is attached to a first beam. The first beam can be of any length and span between other corner frame members. Generally, the first beam is oriented horizontally. In some cases, the first corner frame member is attached to more than more beam. In some cases, the beams are oriented and configured in different directions, for example, one corresponding to the width of a room and the second corresponding to the length of a room. The beams can include openings that correspond and complement the openings of a flange such that connectors can be used to secure and attach the two structures. Connectors, as used herein, refer to those connectors well-known in the art, for example, nuts and bolts, rivets, pins, screws, anchors, washers, retaining rings, threaded rods, and other conventionally known fasteners or connectors.

In some embodiments, the corner frame members can include an insert tube member. The insert tube member can provide a structure to aid in the positioning and alignment of the corner frame member, and in turn, the modular room in which the corner frame member is a part. In some embodiments, the insert tube member is welded to the corner frame member. In some embodiments, the insert tube member is attached to the corner frame member by a connector. In some embodiments, the insert tube member is integrally formed as a part of the corner frame member. In some embodiments, the insert tube member comprises a smaller cross-sectional dimension than the corner frame member.

At the top end of an insert tube member, which can extend above the edge of the corner frame member, a tapered section of the insert tube member having a tapered or angled profile can be exposed. The exposed portion of the insert tube member can be used to guide and align a second corner frame member such that the second corner frame member is positioned vertically above the first corner member. In some such embodiments, the second corner frame member is longitudinally aligned with the first corner member. In some embodiments, the result is that a second modular room is then positioned above a first modular room.

In some embodiments, a modular structure comprising a first modular room having a first corner frame member comprising at least one flange having at least one opening, a first insert tube member, and an exterior surface defining a first exterior opening; and a second modular room having a second corner frame member comprising at least one flange having at least one opening, a second insert tube member, and an exterior surface defining a second exterior opening; and a fastening plate defining a first fastening plate opening and a second fastening plate opening are described herein. In some such embodiments, the first fastening plate opening is aligned with the first exterior opening of the first corner frame member such that a first fastener can be positioned through both the first fastening plate opening and the first exterior opening of the first corner frame member and the second fastening plate opening is aligned with the second exterior opening of the second corner frame member such that a second fastener can be positioned through both the second fastening plate opening and the second exterior opening of the second corner frame member. This arrangement results in the first modular room being positioned adjacent to the second modular room.

In some embodiments, the first fastening plate may have more than two openings. For example, in some cases, the exterior surface of the first corner frame member defines a third exterior opening, the exterior surface of the second corner frame member defines a fourth exterior opening, and the fastening plate defines a third fastening plate opening and a fourth fastening plate opening. In some such embodiments, the third fastening plate opening is aligned with the third exterior opening of the first corner frame member such that a third fastener can be positioned through both the third fastening plate opening and the third exterior opening of the first corner frame member and the fourth fastening plate opening is aligned with the fourth exterior opening of the second corner frame member such that a fourth fastener can be positioned through both the fourth fastening plate opening and the fourth exterior opening of the second corner frame member.

In some such embodiments, the modular structure can further include a third modular room comprising a third corner frame member having at least one flange having at least one opening, a third insert tube member, and an exterior surface defining a fifth exterior opening; a fourth modular room comprising a fourth corner frame member having at least one flange having at least one opening, a second insert tube member, and an exterior surface defining a sixth exterior opening; and a second fastening plate defining a fifth fastening plate opening and a sixth fastening plate opening. In some embodiments, the fifth fastening plate opening is aligned with the fifth exterior opening of the third corner frame member such that a fifth fastener can be positioned through both the fifth fastening plate opening and the fifth exterior opening of the third corner frame member and the sixth fastening plate opening is aligned with the sixth exterior opening of the fourth corner frame member such that a sixth fastener can be positioned through both the sixth fastening plate opening and the sixth exterior opening of the fourth corner frame member. This arrangement results in the third modular room being positioned adjacent to the fourth modular room. Further, the first insert tube member of the first corner frame member is positioned within the third corner frame member, and the second insert tube member of the second corner frame member is positioned within the fourth corner frame member. In some such embodiments, the third modular room is positioned above the first modular room and the fourth modular room is positioned above the second modular room.

In some embodiments, the second fastening plate can include additional openings such that the second fastening can be attached to first corner frame member, the second corner frame member, the third corner frame member, and the fourth corner frame member simultaneously.

In some embodiments, a third fastening plate can be included to attach other corner frame members. With reference to FIG. 2 below, a fastening plate can be used at any of positions 209 and 210 to adjoin and attach corner frame members, at both the top and bottom of different corner frame members.

Certain aspects of the present invention will now be discussed in connection with the attached Figures which illustrate some embodiments of the present invention. Although the description associated with the Figures will focus on embodiments shown in the Figures, it should be understood that only slight modifications need to be made to the components in order to provide systems for constructing modular structures embodying the inventive concepts described in this application. Referring to the Figures, the numbers used within each figure are consistent with every other figure. When a specific feature is labeled in one figure with a specific numeral, the same numeral will be used in other figures when denoting that specific feature.

FIG. 1 shows a frame of a modular room 100. The modular room 100 includes corner frame members 101, intermediate support members 102, and corner frame members 103. Each of corner frame members 101, intermediate support members 102, and corner frame members 103 are vertically oriented, which defines the height of a room. Side beams 107 and side beam 108 each span along different sides of the modular room 100 between the respective vertically oriented corner frame members. As described further below with reference to additional figures, each of the corner frame members 101, 103 comprise an insert tube member 104. The insert tube member 104 can provide a structure to facilitate positioning of a second modular room (not shown in FIG. 1) on top of the modular room 100.

The frame of modular room 100 is shown as having a generally rectangular shape. Modular rooms according to the present invention can be shaped in other configurations, for example, square, trapezoid, or other polygonal shapes, whether regular or irregular.

Although not shown in the FIG. 1, modular room 100 can be further finished. Modular room 100 can include additional framing elements, such as vertical studs, dry wall, plumbing fixtures, electrical components, interior walls, furniture, and other features. The particular structures shown in the figures however provide the support frame and features that permit joining of a plurality of modular rooms to create a modular structure.

FIG. 2 shows a top plan view of a schematic showing a plurality of modular structures 200. FIG. 2 is not drawn to scale but included to illustrate features of the embodiments described herein. The plurality of structures 200 includes modular room 100, a second modular room 201, third modular room 202, fourth modular room 203, fifth modular room 204, and sixth modular room 205. Each of the modular rooms (modular room 100, a second modular room 201, third modular room 202, fourth modular room 203, fifth modular room 204, and sixth modular room 205) can have a structure as shown in FIG. 1. Shown in FIG. 2 are six modular rooms, but any number of modular rooms can be joined to create a modular structure. FIG. 2 shows each of the plurality of modular rooms having similar dimensions and shapes, but as one of skill in the art would appreciate, different sized and/or shaped rooms could be utilized. Corridor 206 is positioned between modular room 100 and fourth modular room 203, between second modular room 201 and fifth modular room 204, and between third modular room 202 and sixth modular room 205.

The modular rooms adjacent to each other, for example, modular room 100 and second modular room 201, are joined at positions 209 and 210. As described in further detail in connection with FIGS. 4 and 5, two modular rooms can be joined at position 209 with a modular steel connector and at position 210 with a modular steel connector. The modular steel connector can be referred to as a fastening plate. The fastening plate can be made of steel and include a plurality of openings that correspond and facilitate the positioning on corner frame members. Position 209 refers to the connector located on the exterior of a modular structure, and position 210 refers to the connector located on the interior of a modular structure, for example, near the corridor 206. Positions 213 and 214 show the position where intermediate support members (e.g., structure 105 in FIG. 1) are located.

The plurality of modular structures 200 can be assembled once each of the individual modular rooms (e.g., modular room 100, a second modular room 201, third modular room 202, fourth modular room 203, fifth modular room 204, and sixth modular room 205) are assembled and positioned for joining. For example, third modular room 202 can be manufactured and assembled in a second location and transported to a particular construction build site and second modular room 201 can be manufactured and assembled in a second location and transported to a particular construction build site. The second modular room 201 and the third modular room 202 can be positioned at the appropriate site and then joined at positions 209 and 210. By having assembled third modular room 202 and second modular room 201 at a remote location and then arriving at a construction build site in a more fully assembled configuration, the joining of adjacent rooms can be affected in a relative short period of time. That is instead of erecting support beams and corner frame members on site, the room comes to the construction site in a near finished form and requires only the attaching and securing of the room to its adjacent structures through the use of a modular steel connector, e.g., a fastening plate. Any number of modular rooms can be joined to provide a footprint for a particular structure.

In some cases, after the plurality of modular structures 200 is assembled and joined to each other, a first level or floor is created. In some embodiments, a second level or floor is then built on top of the plurality of modular structures 200. As described further in connection with FIGS. 3A and 3B, a second modular room can be placed on top of a first modular room through the use of and aid by insert tube members and corner frame members that assist and guide in the proper positioning of a modular structure. FIG. 9 shows an exemplary modular structure 900 where a plurality of modular rooms are positioned adjacent to each other to form a floor or level (generally in a single plane) as well as a plurality of modular rooms being positioned on top of a first floor or level (generally vertically oriented). The modular structure 900 includes 8 levels or floors of modular rooms. One of skill in the art would understand that more or less floor or levels comprising modular rooms could be utilized embodying the present invention.

FIG. 3A shows a corner frame member 101. The corner frame member 101 in FIG. 3A has a generally square cross-dimensional shape (as further shown in FIG. 3B which is a cross-sectional view along the B-B axis). Other cross-dimensional shapes can be utilized without departing from the spirit of the present disclosure. As shown in FIG. 3B, the corner frame member is a tubular structure within a hollow channel defined by side walls 301. In some embodiments, corner frame member 101 is a tubular structure having a void or passage in the interior of the member. The corner frame member 101 includes a first flange 302 and a second flange 303 that each extend from the corner frame member 101. The first flange 302 and second flange 303 can provide a surface to attach the respective flange, and in turn the corner frame member 101, to a side beam or other structure. The first flange 302 and second flange 303 can be welded, or joined, to corner frame member 101. As shown in FIG. 3A and FIG. 3B, the first flange 302 and second flange 303 of the corner frame member 101 are positioned on two adjacent faces of the corner frame member 101 each at a substantially right angle. In other embodiments, the flanges can be positioned on one, two, three or four faces of a support member according to the design of the particular modular structure. In some embodiments, the flanges can be joined or mounted on the corner frame member at an angle other than a right angle, for example, at a 45 degree angle, 30 degree angle, 15 degree angle, and any angle in between, in order to correspond to the desired shape of a modular room.

Each of the flange 302 and flange 303 include a plurality of openings 308 through which a connector 304, e.g., a nut and bolt, can be positioned. The openings 308 are positioned in the flange 302 and flange 303 to correspond to a position of complementary openings on a side beam (not shown in FIGS. 3A and 3B, but shown in FIGS. 4 and 5). In FIG. 3A, the connectors 304 is shown positioned on an exterior surface of the corner frame member.

At the opposed end of the corner frame member 101 from the flange 302 and flange 303, the corner frame member 101 includes an insert tube member 104. The insert tube member 104 can provide a structure that aids in guiding and positioning a first corner frame member onto a second corner frame member. The insert tube member 104 has a maximum cross-sectional dimension that is less than the inner cross-section dimension of the corner frame member 101. The insert tube member 104 comprises a shape with tapered dimensions that facilitates the insertion of the insert tube member 104 into the complementary bottom portion of a second corner frame member. The insert tube member 104 extends beyond the edge of the corner frame member 101 and includes openings 307 through which a connector 304, e.g., a nut and bolt, can be positioned. The openings 307 are positioned in insert tube member 104 to correspond to a position of complementary openings on both corner frame member 101 and a second corner frame member (not shown) that is positioned adjacent and on top of corner frame member 101, for example when stacking one modular room on top of a second modular room.

In some embodiments, the insert tube member 104 is fabricated separately and then joined (e.g., welded) to the corner frame member 101. In some embodiments, the insert tube member 104 can be fabricated with the corner frame member 101 as one continuous structure.

FIG. 4 shows a cross section view of a portion of a modular structure having a plurality of corner frame members, for example, like that could be included at position 209 in FIG. 2. The corner frame members 101 each include flanges 302 and 303 that are attached to side beams 108 and 107, respectively. Connectors 405 attach side beams 108 and 107 to corner frame members 101 via flanges 302 and 303 through the complementary openings that are aligned to facilitate appropriate positioning of the same. After a first corner frame member 101 is first joined to side beam 108 and 107, and in an assembled configuration, for example, like that shown in FIG. 1, and a second corner frame member 101 is first joined to a second side beam 108 and 107, and in an assembled configuration, for example like that shown in FIG. 1, the first corner frame member assembly and the second corner frame assembly can be joined by a fastening plate 400. Fastening plate 400 comprises a plurality of openings that correspond to complementary openings on the exterior of the corner frame members such that a connector 405 (e.g., a nut and bolt) can be positioned through which and thus be attached to both a first corner frame member assembly and a second corner frame member assembly. The fastening plate 400 can ensure proper positioning of a first modular room with respect to a second modular room. A fastening plate 400 can be attached at both the bottom of a corner frame assembly (i.e., the end near the flanges 302 and 303) and the top of the corner frame assembly (i.e., the end near the insert tube member 104). The fastening plate 400 can be made of steel. The fastening plate can secure the first modular room to the second modular room.

In FIG. 4, the fastening plate 400 includes a projection 401 that includes an opening through which a connector 405 can be positioned in order to attach the fastening plate to another structure, for example, an exterior wall (not shown).

FIG. 5, shows a cross section view of a portion of a modular structure having a plurality of corner frame members, for example, like that could be included at position 210 in FIG. 2. The features of the corner frame members 101 and the side beams 108 are similar to that described in connection with FIG. 4. In FIG. 5, the fastening plate 500 does not include a projection, and instead comprises generally flat surface. In some embodiments, the connection of corner frame assemblies shown in FIG. 5 may be positioned in the interior of a modular structure, for example, along corridor 206.

FIGS. 6A and 6B show different views of portions of corner frame member 602, corner frame member 600, and insert tube member 601. FIGS. 6A and 6B show the corner frame member 600 prior to corner frame member 600 being fully seated on corner frame member 602, for example, when positioning a first modular structure on top of a second modular structure. The insert tube member 601 includes tapered edges to guide the positioning of the corner frame member 600 into the proper alignment with corner frame member 602. Fastening plate 603 includes a plurality of openings to align and correspond with openings in corner frame members and insert tube members. FIG. 8 shows an additional embodiment of a support member 802, support member 800, and insert tube member 801. FIG. 8 is similar to FIGS. 6A and 6B showing the different configurations of the insert tube member that facilitates the positioning and alignment of a first support member 800 and a second support member 802. In some embodiments, the embodiment shown in FIG. 8 could be utilized to connect and join intermediate support members, for example like those that may be found a position 213 as shown in FIG. 2 as well as at other positions.

FIG. 7 shows a top view of a cross section of a portion of modular structure having two intermediate support members 702. Intermediate support members 702 include flanges 701 that provides a surface to connect and attach to beams 707 and 708. Flanges 701 each have openings that correspond to a complementary opening in beams 707 and 708 such that a connector 405 (e.g., nut and bolt) can be positioned and affixed the beams 707 and 708 to the support member 702. Support member 702 can be positioned in the interior of a wall, rather than a corner of a modular room.

As used herein, the terms “invention,” “the invention,” “this invention” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to”) unless otherwise noted.

As used herein, when an element is referred to as being “on,” “attached” to, “connected” to, “couple” with, “contacting,” “joined,” etc., another element, it can be directly on, attached to, connected to, coupled with, contacting, or joined to the other element or intervening elements may also be present. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.

As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

Various embodiments of the invention have been described in fulfillment of the various objectives of the invention. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous modifications and adaptations thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the present invention as defined in the following claims.

Claims

1. A modular structure system comprising:

a first corner frame member comprising at least one flange having at least one opening, a first insert tube member, and an exterior surface defining a first exterior opening;

a second corner frame member comprising at least one flange having at least one opening, a second insert tube member, and an exterior surface defining a second exterior opening, and

a fastening plate defining a first fastening plate opening and a second fastening plate opening,

wherein the first fastening plate opening is aligned with the first exterior opening of the first corner frame member such that a first fastener can be positioned through both the first fastening plate opening and the first exterior opening of the first corner frame member and the second fastening plate opening is aligned with the second exterior opening of the second corner frame member such that a second fastener can be positioned through both the second fastening plate opening and the second exterior opening of the second corner frame member.

2. The modular structure system of claim 1, wherein

the exterior surface of the first corner frame member defines a third exterior opening,

the exterior surface of the second corner frame member defines a fourth exterior opening,

the fastening plate defines a third fastening plate opening and a fourth fastening plate opening, and

wherein the third fastening plate opening is aligned with the third exterior opening of the first corner frame member such that a third fastener can be positioned through both the third fastening plate opening and the third exterior opening of the first corner frame member and the fourth fastening plate opening is aligned with the fourth exterior opening of the second corner frame member such that a fourth fastener can be positioned through both the fourth fastening plate opening and the fourth exterior opening of the second corner frame member.

3. The modular structure system of claim 1, wherein the first corner frame member comprises steel and the second corner frame member comprises steel.

4. The modular structure system of claim 1, wherein the at least one flange of the first corner member is attached to a first beam.

5. The modular structure system of claim 1, wherein the first insert tube member comprises a smaller cross-sectional dimension than an inner cross-section dimension of the first corner frame member such that the first insert tube member is positioned at least partially within the first corner frame member.

6. The modular structure system of claim 1, wherein the first insert tube member is welded to the first corner frame member.

7. The modular structure system of claim 1, wherein the first insert tube member comprises a tapered profile.

8. A modular structure comprising:

a first modular room comprising a first corner frame member comprising at least one flange having at least one opening, a first insert tube member, and an exterior surface defining a first exterior opening;

a second modular room comprising a second corner frame member comprising at least one flange having at least one opening, a second insert tube member, and an exterior surface defining a second exterior opening;

a fastening plate defining a first fastening plate opening and a second fastening plate opening,

wherein the first fastening plate opening is aligned with the first exterior opening of the first corner frame member such that a first fastener can be positioned through both the first fastening plate opening and the first exterior opening of the first corner frame member and the second fastening plate opening is aligned with the second exterior opening of the second corner frame member such that a second fastener can be positioned through both the second fastening plate opening and the second exterior opening of the second corner frame member.

9. The modular structure of claim 8, wherein

the exterior surface of the first corner frame member defines a third exterior opening,

the exterior surface of the second corner frame member defines a fourth exterior opening,

the fastening plate defines a third fastening plate opening and a fourth fastening plate opening, and

wherein the third fastening plate opening is aligned with the third exterior opening of the first corner frame member such that a third fastener can be positioned through both the third fastening plate opening and the third exterior opening of the first corner frame member and the fourth fastening plate opening is aligned with the fourth exterior opening of the second corner frame member such that a fourth fastener can be positioned through both the fourth fastening plate opening and the fourth exterior opening of the second corner frame member.

10. The modular structure of claim 9, further comprising:

a third modular room comprising a third corner frame member comprising at least one flange having at least one opening, a third insert tube member, and an exterior surface defining a fifth exterior opening;

a fourth modular room comprising a fourth corner frame member comprising at least one flange having at least one opening, a second insert tube member, and an exterior surface defining a sixth exterior opening;

a second fastening plate defining a fifth fastening plate opening and a sixth fastening plate opening,

wherein the fifth fastening plate opening is aligned with the fifth exterior opening of the third corner frame member such that a fifth fastener can be positioned through both the fifth fastening plate opening and the fifth exterior opening of the third corner frame member and the sixth fastening plate opening is aligned with the sixth exterior opening of the fourth corner frame member such that a sixth fastener can be positioned through both the sixth fastening plate opening and the sixth exterior opening of the fourth corner frame member, and

wherein the first insert tube member of the first corner frame member is positioned within the third corner frame member and the second insert tube member of the second corner frame member is positioned within the fourth corner frame member such that the third modular room is positioned above the first modular room and the fourth modular room is positioned above the second modular room.

11. The modular structure of claim 10, wherein:

the exterior surface of the first corner frame member defines a seventh exterior opening,

the exterior surface of the second corner frame member defines a eighth exterior opening, and

the second fastening plate defines a seventh fastening plate opening and an eighth fastening plate opening,

wherein the seventh fastening plate opening is aligned with the seventh exterior opening of the first corner frame member such that a seventh fastener can be positioned through both the seventh fastening plate opening and the seventh exterior opening of the first corner frame member and the eighth fastening plate opening is aligned with the eighth exterior opening of the second corner frame member such that an eighth fastener can be positioned through both the eighth fastening plate opening and the eighth exterior opening of the second corner frame member.

12. The modular structure of claim 10, wherein the first insert tube member comprises a smaller cross-sectional dimension than an inner cross-section dimension of the first corner frame member such that the first insert tube member is positioned at least partially within the first corner frame member and wherein the cross-sectional dimension of the first insert tube member is smaller than an inner cross-section dimension of the third corner frame member such that the first insert tube member is positioned at least partially within the third corner frame member.

13. The modular structure of claim 8, wherein the first corner frame member comprises steel and the second corner frame member comprises steel.

14. The modular structure of claim 8, wherein the at least one flange of the first corner member is attached to a first beam.

15. The modular structure of claim 8, wherein the first insert tube member comprises a smaller cross-sectional dimension than an inner cross-section dimension of the first corner frame member such that the first insert tube member is positioned at least partially within the first corner frame member.

16. The modular structure of claim 8, further comprising a third fastening plate and wherein the first modular room comprises a fifth corner frame member and the second modular room comprises a sixth corner frame member, and the third fastening plate is attached to the fifth corner frame member and the sixth corner frame member.

17. The modular structure of claim 16, wherein the third fastening plate is positioned at an opposite end of the first modular room than the first fastening plate.