CONSTRUCTION OF LOW- AND MID-RISE BUILDINGS UTILIZING STRUCTURALLY HYBRID WALL, ROOF, OR FLOOR ASSEMBLIES

Abstract

Disclosed is a system and method for constructing low- and mid-rise buildings combining structurally inter-dependent components of conventional Panelized construction and conventional Structural frame construction systems to achieve greater efficiencies of overall building energy use and structural performance than conventional applications of either system alone allows.

Description

BACKGROUND OF THE INVENTION

Current low- and mid-rise building construction (up to 5 floor levels for the purposes of this disclosure) overwhelmingly relies on one of two primary means of creating structural resistance to gravity loading in buildings: 1. Structurally distributive (commonly known as Stick-Built or Stick-Framing), and 2. Structurally framed with non-load bearing infill walls (commonly known as Column and Beam or Structural Frame). Both systems have been in ubiquitous use for centuries, with significant optimizations introduced with the advent of industrial processes in the early 20th Century and are currently fully optimized relative to the priorities of the times in which they were industrialized, specifically ease of erection and minimized cost. In general, the optimization of a system also defines that system's limitations, and in the specific case of these two building construction systems, those limitations significantly limit possible efficiencies relative to two primary 21^st Century imperatives: reduction or elimination of Embodied Carbon and reduction or elimination of Operational Energy usage. For the purposes of this disclosure, Embodied Carbon is the sum of all energy expenditures necessary to manufacture, deliver, and assemble components of a building project, expressed in terms of Carbon expenditures necessary for these tasks. For the purposes of this disclosure, Operational Energy is the amount of energy of all types consumed in the ongoing operation of an occupied building.

Two economy-of-scale optimizations developed to increase the speed and constructional efficiency of Stick-Built construction are industrial processes known commonly as Panelized construction and Modular construction. In both Panelized and Modular processes, the act of Stick-Framing is simply moved into the controlled environment of a factory for significant portions of the building process. Panelized techniques create stick-framed segments of a Wall, Roof, or Floor assembly for on-site assembly, while Modular processes create stick-framed, structurally independent boxes comprised of complete Wall, Roof, or Floor assemblies. All optimizations and limitations of conventional stick-building remain fully intact in the final product of both processes. To maximize economies of scale, Panelized and Modular components are manufactured in permanent, centralized facilities of industrial scale and process, and as a direct consequence of this centralized manufacturing model, rely upon suppling building sites many hundreds of miles away for economic viability.

Stick Framing techniques, including Panelized and Modular construction techniques, are structurally distributive, i.e.: all members of all assemblies are structural and are sized and arrayed to carry and distribute gravity loads (weight) as a primary system attribute. Additionally, horizontal and vertical members provide attachment surfaces for interior and exterior closure materials of standard dimensions. Economies of scale in Panelized and Modular construction techniques generally favor larger and fewer and consequently heavier Panels and Modules, the primary constraint on size being physical and regulatory transport limitations from factory to job site. As a consequence of the above, Panelized and Modular construction techniques result in significant high Embodied energy intensities in the fabrication, movement, and installation of Panels and modules, as well as significant material intensities resulting from the need to resist the enormous stresses imposed on these Panels and modules during their fabrication, movement, transport, and installation.

Structural frame construction techniques concentrate gravity loads from horizontal and vertical surfaces into horizontal beams and vertical columns. Non-load bearing infill assemblies between columns are constructed in a manner similar to Stick-Framing, primarily to create vertical and horizontal attachment surfaces for interior and exterior closure materials. This system results in significant material intensities in the structural frame to resist gravity forces, without resulting in any significant offsetting efficiencies in Wall, Roof, or Floor assemblies because of the necessity of transferring the weight of interior and exterior finished surfaces, materials, and assemblies, as well as structural and live loads, directly to the horizontal and vertical members of the structural frame.

Given current, long-standing techniques and priorities of optimization, neither structurally distributive systems or structural frame systems can be re-optimized to 21^st century priorities and remain as distinct systems without compromising overall structural integrity or incurring unacceptable cost penalties.

One important and readily quantifiable indicator of thermal performance (a primary component of Operational Energy usage intensity) of thermally exposed Wall, Roof, or Floor assemblies, together referred to as the ‘Thermal Envelope’, is called the ‘Framing Factor’. The Framing Factor represents the percentage of surface area of the Thermal Envelope where Framing members (load bearing or non-load bearing members providing attachment surfaces for interior and exterior closure materials) create a direct physical connection between the interior and exterior facing closure layers of Wall. Roof, or exposed Floor Assemblies. This direct connection is commonly referred to as a Thermal Bridge. Because Framing members are either poor thermal insulators (in the case of wood) or thermal conductors (in the case of steel), Thermal Bridging results in a significant degradation of the overall performance of the Thermal Envelope as regards its ability to resist transfer of thermal energy between interior and exterior environments. This degradation of overall Operational Energy usage performance can be up to 24% in a wood-framed wall assembly, and over 60% in a steel-framed wall assembly.

It is important to note that in context of reducing Operational Energy, it is not the absolute amount of wood or steel in a Wall, Floor, or Roof assembly, but the amount of wood or steel in a Wall, Floor, or Roof assembly acting as Thermal Bridges. In current legacy construction techniques, herein identified as structurally distributive systems and structural frame systems, these systems by their nature fundamentally require all Framing members to be Thermal Bridges. The contemplated hybrid system in this disclosure significantly reduces the overall amount of Framing members acting also as Thermal Bridges while achieving similar structural capabilities.

TECHNICAL FIELD

The present invention relates generally to the building construction industry and relates specifically to a building construction system and method for constructing low- and mid-rise buildings utilizing structurally inter-dependent Panelized building construction techniques combined with Structural Frame building construction techniques to effect a structurally hybridized system and method of construction.

SUMMARY OF THE INVENTION

The current Invention proposes a new structurally hybrid system of inter-dependent Panels and Column and Beam Framing members. In a preferred embodiment, the current invention concerns itself with wood construction.

In the proposed new structurally hybrid system, Panels are optimized for 21^st Century concerns, i.e.: minimization of overall Embodied Carbon and minimization of ongoing Operational Energy usage. As a result of these new optimizations, the Panelized construction components of the proposed hybrid system are significantly optimized in material disposition and cannot, by themselves, function structurally as an independent system. Additionally, Column and Beam Framing components of the proposed hybrid system are significantly reduced in material intensity, a system optimization which cannot, of itself, function structurally as an independent system. However, as an inter-dependent hybrid of optimized Structurally Distributive and optimized Structural Column and Beam systems, the proposed new structurally hybrid system of the current invention maintains equivalent overall structural properties with significant improvements in overall Operational Energy usage and significant reduction of overall Embodied Carbon intensity of Wall, Roof, or Floor assemblies as compared with current Structurally Distributive and Structural Column and Beam construction methodologies applied as discrete systems as described above.

In the proposed structurally hybrid system of the current invention, Wall, Roof, or Floor Panels, relieved of the necessity of being primary structural components, are optimized to minimize Thermal Bridging. An additional benefit is an overall reduction of material use intensity in Wall, Roof, or Floor Panel closure assemblies.

Additionally, in the proposed structurally hybrid system of the current invention, Structural Column and Beam components, relieved of the necessity of being primary structural components, are reduced in frequency, reducing Thermal Bridging where structural columns and beams within the Thermal Envelope assembly create zones of reduced thermal resistance. An additional benefit is an overall reduction of material use intensity in Column and Beam components.

In a preferred embodiment, an additional significant innovation of the current Invention is minimized Panel size. In the proposed hybrid system of the current invention, to reduce the Embodied Carbon usage penalty incurred by conventional industrial-scale manufacturing and construction practices, all Panels and inter-dependent structural Framing members necessary to fully enclose a complete exterior weather-tight Building Envelope, as well as all Panels and inter-dependent Framing members necessary to fully enclose interior dependent spaces (bathrooms, bedrooms, storage, mechanical, and the like) are sized to be readily manufactured, moved and erected by no more than 2 persons, with no specific expertise and without the aid of industrial-scaled machines or apparatuses such as cranes for lifting and placing of individual Panels and components.

In a preferred embodiment, reduced weight and size of individual system components, allowing non-industrial scale manufacturing, loading and unloading for shipping and transport, as well as on-site assembly, significantly reduces the overall Embodied Carbon profile of a building project: Manufacturing can temporarily occur close to the building site, in any available space of appropriate size, rather than in industrial-sized permanent facilities, resulting in reduced Carbon impact of long distance shipping from a centralized facility to a construction site, potentially many hundreds of miles away. Additionally, in a preferred embodiment, ordinary small power tools and low energy intensity processes are sufficient to produce, transport, and erect all building components, further reducing the Embodied Carbon profile of a given building project.

In contrast to current centralized and industrial-scaled manufacturing techniques for Panelized and Modular construction, the current invention contemplates an agile and multi-centered manufacturing approach, allowing dynamic and rapid creation, moving, expanding, contracting, and redeployment of manufacturing facilities as best fits immediate demand for this product across multiple regions and markets.

In a preferred embodiment, an additional benefit of reduced weight and size of individual building components is that many building sites, such as crowded urban areas, that are inaccessible to large, mechanized equipment become readily accessible to construction practices based on utilizing small-scale components which can be moved and erected manually by 2 persons, as described in this disclosure.

In a preferred embodiment of the current Invention, many interior components such as intermediate flooring (in multi-story configurations) and Interior partitioning assemblies may also be created as components utilizing the disclosed structural hybrid system and method, and of such size, weight, and configuration to maximize structural material use efficiency while designed to be readily assembled, shipped, and erected by no more than 2 persons without aid of industrial-scale lifting devices or apparatuses.

An additional benefit of a preferred embodiment is that it can, by its nature, be completely taken apart and moved, as well as partially taken apart and expanded or reconfigured, by no more than 2 persons, reusing all disassembled pieces allowing virtually waste-free disassembly and reconfiguration, without aid of industrial-scaled lifting devices or apparatuses.

Additionally, as a direct benefit of the decentralized and non-permanent nature of the herein described manufacturing model of the contemplated system and method, new manufacturing facilities can be quickly set up and made operational as a consequence of direct and immediate need, such as in response to a natural disaster.

It is important to note that the contemplated Wall, Roof, or Floor assemblies can be utilized as independent assemblies or as co-dependent assemblies in any combination without departing from the spirit and scope of the current invention as generally defined in this disclosure.

It will be apparent to those of ordinary skill in the art that the contemplated system and method of the current invention can be readily applied without limitation to a wide variety of building configurations, types, and occupancies currently utilizing Stick-Framed, Column and Beam, Panelized, and Modular systems and methodologies for low- to mid-rise construction projects, with attendant benefits as described above.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. While the present disclosure has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by one of ordinary skill in the art that many modifications and variations may be made therein without departing from the spirit and scope as generally defined in this disclosure. The descriptions of the various embodiments of the present invention have been presented for purposes of illustration only and are not intended to be exhaustive or prescriptive or for purposes of limitation. The scope of the present invention is therefore not defined by the brief description of the several views of the drawings of the invention, but by the Claims. The foregoing and other features and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIGS. 1A-B illustrate general Elevation and cut-through Plan views of Structural Framing components in a representative segment of a conventionally constructed Stick-Framed Wall;

FIG. 1A illustrates a general Elevation view of Structural Framing components in a representative segment of a conventionally constructed Stick-Framed Wall;

FIG. 1B illustrates a general cut-through Plan view of Structural Framing components in a representative segment of conventionally constructed Stick-Framed Wall;

FIGS. 2A-B illustrate general Elevation and cut-through Plan views of Structural Framing components in a representative segment of Wall illustrating a preferred embodiment of the Current Invention;

FIG. 2A illustrates a general Elevation view of Structural Framing components in a representative segment of Wall illustrating a preferred embodiment of the Current Invention;

FIG. 2B illustrates a general cut-through Plan view of Structural Framing components in a representative segment of Wall illustrating a preferred embodiment of the Current Invention;

FIGS. 3A-B illustrate general 3-dimensional views of Structural Framing component intensity in a representative segment of conventionally constructed Stick-Framed Wall, Roof, or Floor (FIG. 3A) shown in contrast to a representative segment of equal size and dimension of a preferred embodiment of the Current Invention (FIG. 3B);

FIG. 3A illustrates a general 3-dimensional view of Structural Framing component intensity in a representative segment of conventionally constructed Stick-Framed Wall, Roof, or Floor;

FIG. 3B illustrates a general 3-dimensional view of Structural Framing component intensity in a representative segment of a preferred embodiment of the Current Invention Wall, Roof, or Floor;

FIG. 4 illustrates a multiplicity of views of the various components utilized in a preferred embodiment to create 48″×24″ and 48″×48″ Opaque Wall Panels;

FIG. 5 illustrates a multiplicity of views of the various components and Panels utilized in a preferred embodiment to create 24″×24″ and 24″×48″ Opaque Outside Wall Corner Panels;

FIG. 6 illustrates a multiplicity of views of the various components utilized in a preferred embodiment to create 48:×24″ and 48″×48″ Wall Window Panels;

FIG. 7 illustrates a multiplicity of views of the various components utilized in a preferred embodiment to create a 48″×96″ Exterior Door Wall Panel;

FIG. 8 illustrates a multiplicity of views of the various components utilized in a preferred embodiment to create a 24″×96″ Floor Panel;

FIG. 9 illustrates a multiplicity of views of the various components utilized in a preferred embodiment to create a 24″×192″ Roof Panel;

FIG. 10 illustrates an exploded cross-sectional view of the various Panels and structural components utilized in a preferred embodiment to create an exemplary complete Wall, Roof, or Floor enclosure assembly;

FIG. 11 illustrates an unexploded cut-through Plan view of the various components utilized in a preferred embodiment to create an exemplary complete enclosure assembly.

All numerical dimensions, quantities, or measuring systems recited in this specification describe a preferred embodiment only and are not intended as prescriptive or for purposes of limitation. Additionally, it will be readily apparent to one of average skill in the art that these dimensional references have metric analogues in those countries that commonly utilize a Metric measuring system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

While the present disclosure has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by one of ordinary skill in the art that many modifications and variations may be made therein without departing from the spirit and scope as generally defined in this disclosure. The descriptions of the various embodiments of the present invention have been presented for purposes of illustration only and are not intended to be exhaustive or prescriptive or for purposes of limitation. Descriptions and Terminology used herein have been chosen to best explain the principles of the embodiments, the practical application or technical improvement over systems, methods, and techniques currently predominant in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein. The scope of the present invention is therefore not defined by the detailed description of the invention, but by the Claims.

Also, the grammatical articles “one”, “a”, “an”, and “the”, as used in this specification, are intended to include “at least one” or “one or more”, unless otherwise indicated. Thus, the articles are used in this specification to refer to one or more than one (i.e., to “at least one”) of the grammatical objects of the article. By way of example, “a component” means one or more components, and thus, possibly, more than one component is contemplated and can be employed or used in an implementation of the described processes, compositions, and products. Further, the use of a singular noun includes the plural, and the use of a plural noun includes the singular, unless the context of the usage requires otherwise.

Also, only structural materials, systems and assemblies are revealed in these drawings, but it will be readily apparent to one of average skill in the art that non-structural features such as, but not limited to, insulating materials, weather and water resistant layers, windows, doors, exterior and interior finish materials, as well as systems such as electrical, HVAC, and plumbing can be integrated or applied in a multiplicity of combinations with the materials, systems and assemblies illustrated to create complete, climate- and use-appropriate exterior Wall, Roof, or Floor assemblies as components of the overall exterior envelope of a building project, as well as use-appropriate interior Wall or Floor assemblies consistent with the scope and spirit of the described embodiments.

Also, various features and characteristics of the invention are described in this specification to provide an overall understanding of the disclosed Wall, Roof, or Floor components and method of assembly. It is understood that the various features and characteristics described in this specification can be combined in any suitable manner regardless of whether such features and characteristics are expressly described in combination in this specification. The Applicant expressly intends such combinations of features and characteristics to be included within the scope of this specification. As such, the claims can be amended to recite, in any combination, any features and characteristics expressly or inherently described in, or otherwise expressly or inherently supported by, this specification. Furthermore, the Applicant reserves the right to amend the claims to affirmatively disclaim features and characteristics that may be present in the prior art, even if those features and characteristics are not expressly described in this specification. Therefore, any such amendments will not add new matter to the specification or claims and will comply with written description and sufficiency of description requirements (e.g., 35 U.S.C. sctn. 112(a) and Article 123(2) EPC). The Wall, Roof, or Floor structures and methods disclosed in this specification can comprise, consist of, or consist essentially of the various features and characteristics described in this specification.

Also, any numerical dimensions, quantities, or measuring systems recited in this specification describe a preferred embodiment only and are not intended as prescriptive or for purposes of limitation. All referenced dimensions for dimensional lumber are referenced as nominal dimensions (in inches), as is customary in wood construction practices in countries utilizing the Imperial (feet and inches) measuring system. It is readily apparent to one of average skill in the art that these dimensional references have metric analogues in those countries that commonly utilize a Metric measuring system.

FIGS. 1A-B illustrate general Elevation and cut-through Plan views of Structural Framing components in a representative segment of conventionally constructed Stick-Framed Exterior Wall; Referring to FIG. 1A, the primary structural components of a conventional Stick-Framed exterior wall assembly using conventional wood-stud-framed construction techniques is shown in Elevation view, comprised of a Double Top Plate 100 at the top of the assembly, vertical studs, typically spaced at 16 inches on center 101 in the intermediate portion of the assembly, and a single Bottom Plate 102 providing a positive structural connection between the vertical stud wall assembly and the horizontal floor deck assembly. It is readily apparent to one of average skill in the art that these structural members comprising the primary structural components of a typical Stick-Framed wall assembly also represent Thermal Bridges as described previously in this disclosure. It is also well known to one of average skill in the art that Panelized and Modular construction techniques are simply factory-built forms of Stick-Framed construction as described previously in this disclosure. Referring to FIG. 1B, a general Plan cut-through view of Structural Framing components in a representative segment of conventionally constructed Stick-Framed Exterior Wall is shown, comprised of vertical studs, typically spaced at 16 inches on center 110 in the intermediate portion of the assembly. A single Bottom Plate 111 providing a positive structural connection between the vertical stud wall assembly and the horizontal floor deck assembly is shown below the vertical studs. An Exterior sheathing layer 109 is typically applied on the exterior face of the vertical studs 110, and an interior finish layer 112 is typically applied on the interior (inside) face of the vertical studs. It is readily apparent to one of average skill in the art that the exterior sheathing layer 109 as well as the interior finish layer 112 can be of a multiplicity of types and configurations, thicknesses, and sizes without departing from the scope and spirit of the described embodiments.

FIGS. 2A-B illustrate general Elevation and cut-through Plan views of Structural Framing components in a representative segment of Exterior Wall of a preferred embodiment of the current invention, dimensionally similar to the representative segment of conventionally constructed Stick-Framed Exterior Wall illustrated in FIGS. 1A-B. Referring to FIG. 2A, the primary Structural Framing components in a representative segment of Exterior Wall of a preferred embodiment of the current invention is shown in Elevation view, comprised of a Single Top Plate 200 at the top of the assembly, vertical studs, spaced at 48 inches on center 201 in the intermediate portion of the assembly, intermediate lateral connecting members 202, and a single Bottom Plate 203 providing a positive structural connection between the vertical stud wall assembly and the horizontal floor deck assembly. It is readily apparent to one of average skill in the art that these structural members comprising the primary structural components of a representative segment of a preferred embodiment assembly also represent a significant reduction in Thermal Bridges as compared with a similar representative segment of conventionally constructed Stick-Framed Exterior Wall as described previously in this disclosure. Referring to FIG. 2B, a general cut-through Plan view of Structural Framing components in a representative segment of Exterior Wall of a preferred embodiment of the current invention is shown, comprised of vertical studs, spaced at 48 inches on center 212 in the intermediate portion of the assembly. A single Bottom Plate 210 providing a positive structural connection between the vertical stud wall assembly and the horizontal floor deck assembly is shown below the vertical studs. In a preferred embodiment of the current invention, Exterior Wall Panels 209 are typically affixed between the vertical studs and aligned with the exterior face of the vertical studs 212, and an interior finish layer is applied on the interior (inside) face of the vertical studs 211. It is readily apparent to one of average skill in the art that all components, types, Panels, and assemblies, without limitation, can be of a multiplicity of material types and configurations, thicknesses, component types and sizes without departing from the scope and spirit of the described embodiments. Additionally, it is readily apparent to one of average skill in the art that the interior finish layer 211 can be of a multiplicity of material types and configurations, thicknesses, and sizes without departing from the scope and spirit of the described embodiments.

FIGS. 3A-B illustrate general 3-dimensional views of Structural Framing component intensity in a representative segment of conventionally constructed Stick-Framed Wall, Roof, or Floor contrasted with a similar representative segment Wall, Roof, or Floor Structural Framing component intensity of a preferred embodiment of the current invention. FIG. 3A is shown as a representative segment of Stick-Framed construction 310 of a representative size, dimension, and structural component type. FIG. 3B illustrates representative structural Framing component intensity of similar size, dimension, and structural component type. to FIG. 3A of a preferred embodiment of the Current Invention 311. As illustrated in FIG. 3B contrasted with FIG. 3A, the overall reduction in Structural Framing intensity is reduced by approximately 45% in the preferred embodiment of similar size, dimension, and component type. In wood-framed construction methodologies structural components also typically effect Thermal Bridges as described previously in this disclosure. It is readily apparent to one of average skill in the art that the overall reduction in Thermal Bridging intensity is reduced by a similar amount to the overall reduction in referenced structural Framing intensity.

FIG. 4 illustrates a multiplicity of views of the various components utilized in a preferred embodiment to create 48″×24″ and a 48″×48″ opaque Exterior Wall Panels. Referring to FIG. 4, 400 illustrates exterior elevational views of a 48″×24″ opaque Panel as well as 48″×48″ opaque Panels, 401 illustrates the interior elevational view of a 48″×24″ opaque Panel. Items 402, 403, and 404 illustrate a sectional view of components of a 48″×24″ opaque Panel, where 402 illustrates a continuous top plate, 404 illustrates a continuous bottom plate, and 403 illustrates a sheathing Panel. It will be readily apparent to one of average skill in the art that these components can be of a multiplicity of types and configurations, thicknesses, and sizes without departing from the scope and spirit of the described embodiments. Referring again to FIGS. 4, 405 and 407 illustrate interior elevation views of 48″×48″ opaque Panels, and 406 and 408 illustrate sectional views of 48″×48″ opaque Panels. It will be readily apparent to one of average skill in the art that these components can be of a multiplicity of types and configurations without departing from the scope and spirit of the described embodiments. Referring again to FIG. 4, 409 illustrates a cut-through plan view of a 48″ wide Panel. Referring again to FIG. 4, 410 illustrates a sectional view of a continuous sectional wall base plate. Referring again to FIG. 4, 411 illustrates a plan view of vertical structural component. It will be readily apparent to one of average skill in the art that the illustrated components and Panel assemblies can be of a multiplicity of types and configurations, thicknesses, and sizes without departing from the scope and spirit of the described embodiments, and that standard and non-standard improvements to conventional exterior wall assemblies such as windows, penetrations for ventilation, electricity, plumbing and the like are anticipated and can be readily accommodated by the current invention as described in the preferred embodiment and these specifications.

FIG. 5 illustrates a multiplicity of views of the various components and Panels utilized in a preferred embodiment to create 24″×24″ and a 24″×48″ opaque Exterior Wall Corners. In a preferred embodiment, 24″ and 48″ corner assemblies are made up of 2 Panels, herein referred to as ‘left’ and ‘right’ Panels. Usage of this specific nomenclature should in no way be construed as a limitation placed on the use, configuration, or adaptability of these Panels as single components or as a combined corner assembly. It will be readily apparent to one of average skill in the art that corners can be composed of a multiplicity of types and configurations, thicknesses, assemblies, and sizes without departing from the scope and spirit of the described embodiments. Referring to FIGS. 5, 500 and 503 illustrate exterior elevational views of 24″×24″ and 24″×48″ ‘left’ and ‘right’ opaque corner Panels that when combined as illustrated in 514 create a complete corner assembly. It will be readily apparent to one of average skill in the art that corners can be composed of a multiplicity of types and configurations, thicknesses, assemblies, and sizes without departing from the scope and spirit of the described embodiments. Referring again to FIGS. 5, 501 and 504 illustrate interior elevational views of 24″×24″ and 24″×48″ ‘left’ and ‘right’ opaque corner Panels that when combined as illustrated in 514 create a complete corner assembly. It will be readily apparent to one of average skill in the art that corners can be composed of a multiplicity of types and configurations, thicknesses, assemblies, and sizes without departing from the scope and spirit of the described embodiments. Referring again to FIGS. 5, 505, 506, and 507 illustrate sectional views of 24″×24″ and 24″×48″ ‘left’ and ‘right’ opaque corner Panels that together create a complete corner assembly. Referring again to FIG. 5, 508 illustrates a section view of a continuous bottom plate. Referring again to FIG. 5, 509 illustrates a cut-through plan view of a ‘left’ Panel utilized in a preferred embodiment to create part of a complete 24″×24″ and a 24″×48″ opaque Exterior Wall Corner assembly. Referring again to FIG. 5, 511 illustrates a cut-through plan view of an ‘right’ Panel utilized in a preferred embodiment to create part of a complete 24″×24″ and a 24″×48″ opaque Exterior Wall Corner assembly. Referring again to FIGS. 5, 510 and 512 illustrate a cut-through Plan view of vertical structural components. Referring again to FIG. 5, 514 illustrates a cut-through Plan view of components and Panels used to create a complete 24″ or 48″ corner Panel assembly. It will be readily apparent to one of average skill in the art that the illustrated Panels can be of a multiplicity of types and configurations, thicknesses, assemblies, and sizes without departing from the scope and spirit of the described embodiments, and that standard improvements to conventional exterior wall assemblies such as windows, penetrations for ventilation, electrical work, plumbing and the like are anticipated and can be readily accommodated by the current invention as described in the preferred embodiment and these specifications.

FIG. 6 illustrates a multiplicity of views of the various components utilized in a preferred embodiment to create 48″×24″ and 48″×48″ Exterior Window Wall Panels. Referring to FIG. 6, 600 illustrates an exterior elevational view of a 48″×24″ Exterior Window Wall Panel as well as a 48″×48″ Exterior Window Wall Panel, 601 illustrates the interior elevational view of a 48″×24″ Exterior Window Wall Panel as well as a 48″×48″ Exterior Window Wall Panel. Items 602, 603, and 605 illustrate a sectional view of components of a 48″×24″ Exterior Window Wall Panel, where 602 illustrates a top plate, 605 illustrates a continuous bottom plate, 603 illustrates a sheathing Panel, and 604 illustrates a contemplated premanufactured window unit. It will be readily apparent to one of average skill in the art that these components and premanufactured window units can be of a multiplicity of types and configurations without departing from the scope and spirit of the described embodiments. Additionally, it will be readily apparent to one of average skill in the art that a contemplated finished window assembly may be included in or excluded from this assembly, system, and method without departing from the scope and spirit of the described embodiments. Referring again to FIG. 6, 606 illustrates a sectional view of components of a 48″×48″ Exterior Window Wall Panel. It will be readily apparent to one of average skill in the art that these components can be of a multiplicity of types and configurations without departing from the scope and spirit of the described embodiments. Additionally, it will be readily apparent to one of average skill in the art that a contemplated finished window assembly may be included in or excluded from this assembly, system, and method without departing from the scope and spirit of the described embodiments. Referring again to FIG. 6, 607 illustrates a cut-through Plan view of an Exterior Window Wall Panel. Referring again to FIG. 6, 608 illustrates a cut-through Plan view of a vertical structural component. It will be readily apparent to one of average skill in the art that a multiplicity of window types and installation and attachment techniques can be adapted to this system and method without departing from the scope and spirit of the described embodiments. Additionally, it will be readily apparent to one of average skill in the art that a contemplated finished window assembly may be included in or excluded from this assembly, system, and method without departing from the scope and spirit of the described embodiments.

FIG. 7 illustrates a multiplicity of views of the various components utilized in a preferred embodiment to create a 48″×96″ opaque Exterior Door Wall Panel. Referring to FIG. 7, 700 illustrates an exterior elevational view of a 48″×96″ Exterior Door Panel, and 701 illustrates the interior elevational view of a 48″×96″ Exterior Door Panel. Items 702, 703, 704, 705, 706, and 707 illustrate sectional views of components of a 48″×96″ Exterior Door Panel, where 702 illustrates a continuous top plate, 707 illustrates a continuous bottom plate, 703 illustrates a sheathing Panel, 704 illustrates a top component of a finished Door Frame assembly, and 706 illustrates a sill component of a finished door frame assembly. Referring again to FIG. 7, 705 illustrates a contemplated finished exterior door. It will be readily apparent to one of average skill in the art that a multiplicity of door types and installation and attachment techniques can be adapted to this system and method without departing from the scope and spirit of the described embodiments. Additionally, it will be readily apparent to one of average skill in the art that a contemplated finished door may be included in or excluded from this assembly, system, and method without departing from the scope and spirit of the described embodiments. Referring again to FIG. 7, 708 illustrates a cut-through Plan view of an Exterior Door Wall Panel. Referring again to FIG. 7, 709 illustrates a cut-through Plan view of a 2×6 vertical structural component. Referring again to FIG. 7, 710 illustrates a contemplated finished exterior door, and 711 illustrates a contemplated door swing for the contemplated finished exterior door. It will be readily apparent to one of average skill in the art that a multiplicity of door types and installation and attachment techniques can be adapted to this system and method without departing from the scope and spirit of the described embodiments. Additionally, it will be readily apparent to one of average skill in the art that a contemplated finished door and associated means of opening and closing the contemplated finished door may be included in or excluded from this assembly, system, and method without departing from the scope and spirit of the described embodiments.

FIG. 8 illustrates a multiplicity of sectional views of the various components utilized in a preferred embodiment to create a representative Floor Panel assembly. Referring to FIG. 8, Items 800 and 801 illustrate lateral section views of a Floor Panel as a component of a complete building floor plate, 802 illustrates a lateral section view of a horizontal structural component. Referring again to FIG. 8, item 803 illustrates a continuous Exterior Wall bottom plate, and 804 illustrates a lateral section view of a multiplicity of Floor Panels as a component of a complete floor plate. It will be readily apparent to one of average skill in the art that a multiplicity of floor types and configurations, floor Panel types and configurations, as well as floor component installation and floor component attachment techniques can be adapted to this system and method without departing from the scope and spirit of the described embodiments. Referring again to FIG. 8, 806 illustrates a longitudinal sectional view of a Floor Panel as a component of a complete floor plate, 805 illustrates 48″×96″ or 48″×48″ floor sheathing Panels applied longitudinally across multiple lateral Floor Panels, and 807 illustrates an integrally attached floor sheathing Panel. Referring again to FIG. 8, 808 illustrates a longitudinal sectional view of a horizontal structural component. It will be readily apparent to one of average skill in the art that these components and Panels can be of a multiplicity of types and configurations without departing from the scope and spirit of the described embodiments, and representative assemblies shown are for purposes of illustration only and not intended to be exhaustive, prescriptive, or for purposes of limitation.

FIG. 9 illustrates a multiplicity of sectional views of the various components utilized in a preferred embodiment to create a representative Roof Panel assembly. In a preferred embodiment, roof assemblies are made up of 3 Panels, herein referred to as ‘left’, ‘middle’ and ‘right’ Panels. Usage of this specific nomenclature should in no way be construed as a limitation placed on the use, configuration, or adaptability of these Panels as single components, multiple components, or as a combined roof assembly. Referring to FIG. 9, Items 900, 902, 903 and 910 illustrate lateral section views of Roof Panels as components of a complete roof plate, where 900 illustrates a ‘left’ end Panel, 902 illustrates a ‘middle’ Panel, and 903 illustrates a ‘right’ end Panel. It will be readily apparent to one of average skill in the art that a multiplicity of roof types and configurations, roof Panel types and configurations, as well as roof component supporting members, and roof component installation and roof component attachment techniques can be adapted to this system and method without departing from the scope and spirit of the described embodiments. Referring again to FIG. 9, 901 illustrates a lateral section view of a horizontal structural component. Items 904 and 909 illustrate continuous horizontal nailing edge components, which allow for installation of additional insulation above the wood deck, as well as secure attachment of weatherproofing components such as, but not limited to, sheet metal flashing and membrane roofing. Referring again to FIG. 9, items 905 and 912 illustrate continuous top plate wall components. Referring again to FIG. 9, 906 illustrates a longitudinal sectional view of a Roof Panel as a component of a complete roof plate, 908 illustrates separately attached Roof sheathing Panels, and 907 illustrates a hinged truss component attached to and used to reduce bending stress in the Roof Panel, referred to as item 906. It will be readily apparent to one of average skill in the art that a multiplicity of roof types and configurations, roof Panel types and configurations, as well as roof component supporting members, and roof component installation and roof component attachment techniques can be adapted to this system and method without departing from the scope and spirit of the described embodiments. Referring again to FIG. 9, 911 illustrates the hinged truss component in its folded position for shipping. It will be readily apparent to one of average skill in the art that a multiplicity of roof types and configurations, roof Panel types and configurations, as well as roof component supporting members, and roof component installation and roof component attachment techniques can be adapted to this system and method without departing from the scope and spirit of the described embodiments, and representative assemblies shown are for purposes of illustration only and not intended to be exhaustive, prescriptive, or for purposes of limitation.

FIG. 10 illustrates an exploded cross-sectional view of the various Panels and structural components utilized in a preferred embodiment to create a complete Wall, Roof, or Floor enclosure assembly. Referring to FIG. 10, 1000 illustrates continuous horizontal nailing edge components, which allows for installation of additional insulation above the wood deck, as well as secure attachment of weatherproofing components such as, but not limited to, sheet metal flashing and membrane roofing, and 1001 illustrates 48″×96″ or 48″×48″ sheathing Panels applied longitudinally across multiple lateral Roof Panels 1002 to increase rigidity of the overall Roof system. Referring again to FIG. 10, 1003 illustrates a continuous top plate wall component, 1005 illustrates a vertical structural stud component, and 1012 illustrates a continuous bottom plate wall component. Referring again to FIG. 10, 1004 illustrates a 24″×48″ or 48″×48″ Exterior Window Wall Panel. It will be readily apparent to one of average skill in the art that a contemplated finished window assembly may be included in or excluded from this assembly, system, and method without departing from the scope and spirit of the described embodiments. Referring again to FIG. 10, 1006 illustrates a 24″×48″ or 48″×48″ Exterior Opaque Wall Panel. Referring again to FIG. 10, 1008 illustrates a Floor Panel laterally spanning the width of a preferred embodiment, and 1007 illustrates 48″×96″ or 48″×48″ floor sheathing Panels applied longitudinally across multiple lateral Floor Panels. Referring again to FIG. 10, 1011 illustrates a preferred method of creating a foundational resolution for bringing the weight of the of the overall assembly to the ground, illustrated to provide context for this disclosure of the current invention. It is important to note that no foundation assembly or components are included in the Claims in this disclosure—this is for purposes of illustration only. It will be readily apparent to one of average skill in the art that foundational resolutions for the disclosed current invention can be of a multiplicity of types and configurations without departing from the scope and spirit of the described embodiments. Referring again to FIG. 10, 1010 indicates a hypothetical ground plane to provide context for this disclosure of the current invention. It will be readily apparent to one of average skill in the art that ground plane resolutions for the disclosed current invention, including Floor and Roof solutions provided outside the scope of this disclosure, can be of a multiplicity of types and configurations without departing from the scope and spirit of the described embodiments.

FIG. 11 illustrates an unexploded cut-through Plan view of the various components utilized in a preferred embodiment to create a complete enclosure assembly. Referring to FIG. 11, 1100 illustrates a cut-through plan view of a 2×6 vertical structural component, 1101 illustrates a 48″ wide opaque exterior Panel, 1103 illustrates an exterior door wall Panel, as disclosed in FIG. 7, 1106 illustrates an applied interior finish material, and 1105 illustrates a 24″×24″ exterior wall corner Panel, as disclosed in FIG. 5. Referring again to FIG. 11, 1102 illustrates a cut-through plan view of a contemplated arrangement of interior vertical structural or non-structural components and Panels, of like dimension and application to the disclosed exterior vertical structural components and exterior wall Panels, except in an interior environment and context. It will be readily apparent to one of average skill in the art that these components can be of a multiplicity of types and configurations, sizes, and thicknesses without departing from the scope and spirit of the described embodiments. Additionally, it will be readily apparent to one of average skill in the art that the illustrated overall configuration of components in the preferred embodiment can be arranged in a multiplicity of configurations, including but not limited to: larger and smaller plan configurations, single- and multiple-story configurations, non-rectangular configurations, configurations with a variety of window and door Panels, and stair modules in multiple-story configurations, without departing from the scope and spirit of the described embodiments.

The disclosure set forth above may encompass multiple distinct examples with independent utility. Although each of these has been disclosed in its preferred form(s), the specific examples thereof as disclosed and illustrated herein are not to be considered in a limiting sense, because numerous variations are possible. To the extent that section headings are used within this disclosure, such headings are for organizational purposes only. The subject matter of the disclosure includes all novel and nonobvious combinations and sub-combinations of the various elements, features, functions, or properties disclosed herein. The preceding claims particularly point out certain combinations and sub-combinations regarded as novel and nonobvious. Other combinations and sub-combinations of features, functions, elements, or properties may be claimed in applications claiming priority from this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure.

Claims

1. A hybrid system of structurally inter-dependent prefabricated Panel components and Column and Beam Framing components and method of their production and installation for creation of Wall, Floor, or Roof assemblies of low-rise and mid-rise buildings, including: a plurality of non-structural Wall, Floor, or Roof Panels and a plurality of non-structural Column and Beam Framing members, the mechanical affixment of Panels and Framing members creating structurally hybrid Wall, Floor, or Roof assemblies of equivalent structural properties to conventional stand-alone Stick-framed, Panelized, Modular, and Column and Beam systems and methods of building construction.

2. The hybrid system of claim 1, wherein a plurality of Panel components is of insufficient structural integrity to effect a structurally independent system.

3. The hybrid system of claim 1, wherein a plurality of Column and Beam Framing components is of insufficient structural integrity to effect a structurally independent system.

4. The hybrid system of claim 1, wherein the mechanical affixment of a plurality of Panel components and Column and Beam Framing members creates structurally hybrid Wall, Floor, or Roof assemblies of equivalent structural properties to conventional stand-alone systems.

5. The hybrid system of claim 1, wherein Panel components are prefabricated from pieces, parts, and connectors of standard dimension and ready retail availability.

6. The hybrid system of claim 1, wherein Column and Beam Framing components utilize pieces, parts, and connectors of standard dimension and ready retail availability.

7. The hybrid system of claim 1, wherein a reduced intensity of members subject to Thermal Bridging is effected.

8. The hybrid system of claim 1, wherein reduced component size and weight effects economies of manufacture, shipping, and assembly.

9. The hybrid system of claim 1, wherein completed buildings can be readily partially or fully unassembled and moved or reconfigured and reassembled in whole or in part.

10. The hybrid system of claim 1, wherein the system is applicable to exterior Wall, Roof, or Floor assemblies comprising the Thermal Envelope.

11. The hybrid system of claim 1, wherein the system is applicable to interior Wall, Floor, Intermediate Floor, or Ceiling assemblies defining interior functional areas and spaces.

12. The hybrid system of claim 1, wherein the method of manufacture, shipping, and assembly does not require large scale industrial processes, facilities, or equipment.

13. The Panel components of claim 2, wherein the method of their manufacture allows individual Panel components to be assembled manually by no more than one person.

14. The hybrid system of claim 1, wherein the movement of individual completed components for purposes of organization, loading and unloading, shipping, storage, and assembly can be effected manually by no more than 2 persons without the use of large-scale industrial processes, facilities, or equipment.

15. The hybrid system of claim 1, wherein manufacturing capabilities are effected through small-scale manufacturing facilities of low energy use intensity.

16. The hybrid system of claim 1, wherein expansion of total manufacturing capabilities may be effected by opening a plurality of new small-scale manufacturing facilities of low energy use intensities.

17. The hybrid system of claim 1, wherein rapid expansion of manufacturing capabilities is effected by opening a plurality of temporary small-scale manufacturing facilities of low energy use intensity, especially in response to immediate housing need scenarios, such as natural disasters.

18. The Panel components of claim 2, wherein the placing and mechanical affixment of individual completed Panel components within a hybrid system can be effected manually by no more than 2 persons without the use of large-scale industrial processes, facilities, or equipment.

19. The Column and Beam Framing components of claim 3, wherein the placing and mechanical affixment of individual Framing components within a hybrid system can be effected manually by no more than 2 persons without the use of large-scale industrial processes, facilities, or equipment.

20. The hybrid system of claim 1, wherein complete start-to-finish building assembly may be effected by “Do-It-Yourself” persons or entities, without specialized skills, tools, or industrial-scaled equipment.